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Robotics Maintenance Mastery

Keep the cells running.

A complete course in industrial robot maintenance: safety and lockout for robotic cells, controllers, servo drives and motors, mechanics, end-of-arm tooling, programming for maintenance, networking, preventive maintenance and troubleshooting.

58 chapters in 11 Parts5 deep-dive chapters6 appendices100+ diagrams50+ photographs

Who it is for

Maintenance technicians who support robotic cells, and electricians or mechanics moving into robot maintenance.

What you will learn

  • Robot safety systems and lockout/tagout for robotic cells
  • Controllers, power distribution, servo drives, servo motors, encoders and resolvers
  • Gear reducers and harmonic drives, bearings and lubrication, cable dress packs, balancers and brakes
  • End-of-arm tooling: grippers, welding end effectors, vision-guided tooling and TCP setup
  • Teach pendants, reading robot programs, backup and restore, mastering and zero-point calibration, I/O troubleshooting
  • Industrial networks, fieldbus troubleshooting and PLC-to-robot communication
  • Preventive maintenance schedules, vibration analysis, thermal imaging and accuracy testing
  • Alarm codes and fault diagnosis, collision recovery, and platform chapters for FANUC, ABB, KUKA, Yaskawa Motoman and Universal Robots

How the course works

  • Knowledge Check quizzes throughout the text
  • Platform chapters you can study for the robots in your own plant
  • Read online on any device, with your place and answers saved to your account

Table of contents

Part I - Safety & Foundations5 chapters
  1. 1.Industrial Robot Safety Systems
  2. 2.Lockout/Tagout for Robotic Cells
  3. 3.Robot Anatomy & Coordinate Systems
  4. 4.Types of Industrial Robots & Applications
  5. 5.Reading Robot Electrical Schematics
Part II - Electrical Systems6 chapters
  1. 6.Robot Controller Architecture
  2. 7.Power Supply & Distribution Systems
  3. 7A.Backup Battery Systems & UPS
  4. 8.Servo Drive Systems & Amplifiers
  5. 9.Servo Motor Maintenance & Replacement
  6. 10.Encoder & Resolver Systems
Part III - Mechanical Systems6 chapters
  1. 11.Gear Reducers & Harmonic Drives
  2. 12.Bearings, Seals & Lubrication
  3. 13.Belt & Chain Drive Systems
  4. 14.Cable Management & Dress Packs
  5. 15.Balancer & Counterweight Systems
  6. 15A.Brake Systems & Brake Testing
Part IV - End-of-Arm Tooling5 chapters
  1. 16.Gripper Systems & Tool Changers
  2. 17.Welding End Effectors
  3. 17A.Pneumatic & Hydraulic Tooling
  4. 18.Vision-Guided & Sensor-Based Tooling
  5. 19.Tool Calibration & TCP Setup
Part V - Programming for Maintenance5 chapters
  1. 20.Teach Pendant Operation & Navigation
  2. 21.Understanding Robot Programs
  3. 22.Backup, Restore & File Management
  4. 23.Mastering & Zero-Point Calibration
  5. 24.I/O Configuration & Troubleshooting
Part VI - Communication & Networking4 chapters
  1. 25.Industrial Network Protocols
  2. 26.Fieldbus Troubleshooting
  3. 27.PLC-to-Robot Communication
  4. 28.Remote Monitoring & Diagnostics
Part VII - Preventive Maintenance5 chapters
  1. 29.PM Schedules & Checklists
  2. 30.Grease & Oil Maintenance
  3. 31.Vibration Analysis for Robots
  4. 32.Thermal Imaging & Condition Monitoring
  5. 33.Accuracy Testing & Performance Verification
Part VIII - Troubleshooting6 chapters
  1. 34.Alarm Codes & Error Interpretation
  2. 35.Systematic Fault Diagnosis
  3. 36.Electrical Fault Tracing
  4. 37.Mechanical Fault Diagnosis
  5. 38.Collision Recovery & Joint Realignment
  6. 38A.Intermittent Fault Diagnosis
Part IX - Brand-Specific Platforms5 chapters
  1. 39.FANUC Robots - Maintenance & Diagnostics
  2. 40.ABB Robots - Maintenance & Diagnostics
  3. 41.KUKA Robots - Maintenance & Diagnostics
  4. 42.Yaskawa Motoman - Maintenance & Diagnostics
  5. 42A.Universal Robots - Collaborative Robot Maintenance
Part X - Integration & Advanced Topics5 chapters
  1. 43.Robot Cell Design & Safety Integration
  2. 44.Conveyor & Peripheral Integration
  3. 45.Welding System Integration
  4. 46.Vision System Integration
  5. 47.Multi-Robot Cell Coordination
Part XI - Professional Development11 chapters
  1. 48.Spare Parts Management & Inventory
  2. 49.Documentation & Work Order Systems
  3. 50.Root Cause Analysis & Continuous Improvement
  4. 51.Training New Technicians
  5. 52.Industry 4.0 & Smart Factory Robotics
  6. 53.Robot Installation & Commissioning
  7. 54.Decommissioning & Robot Relocation
  8. 55.Cybersecurity for Industrial Robots
  9. 56.Emerging Technologies & Cobot Trends
  10. 57.Building Your Career Path
  11. 58.Final Review and Professional Next Steps
Appendices6
  1. Common Alarm Code Reference
  2. Torque Specifications & Lubrication Charts
  3. Wiring Diagrams & Connector Pinouts
  4. PM Schedule Templates
  5. Glossary of Robotics Terms
  6. Recommended Tools & Equipment