A robot being 15 or 20 years old doesn't mean it's ready for retirement. Generations like the ABB S4, the KUKA KRC2 or the FANUC R-J3 are still producing in countless plants. With the right maintenance and access to parts, an old robot can be one of the most profitable assets in your installation.
Why an old robot is still profitable
It's amortised, the cell is tuned and debugged, and the staff know it. Maintaining it almost always costs a fraction of replacing the whole installation (new robot, integration, programming, validation). If it does its job and is safe, extending its life is a sensible economic decision.
Critical points to watch
- Gearboxes: lubrication and oil change on schedule; they're the mechanical heart of the robot.
- Batteries: SMB on ABB, pulsecoder on FANUC; change them before losing position.
- Electronics: capacitors and power supplies age; watch for signs of fatigue.
- Wiring: power and data hoses that fatigue with the cycles.
- Obsolescence: identify which parts are no longer made and secure their supply.
Parts for older generations
The biggest risk of an old robot isn't mechanical, it's supply: discontinued parts. Here, reconditioned and tested parts are the usual way to keep it running. Having that access —boards, power supplies, motors, teach pendants— makes the difference between keeping production going or being stopped.
When to maintain and when to replace
It's worth continuing to maintain while breakdowns are sporadic and the accumulated cost stays low. Consider replacing when breakdowns become frequent and costly, when the robot no longer delivers the required productivity or safety, or when the maintenance spend approaches that of a new unit. It's a decision with history data, not by intuition.
A plan tailored to your fleet
At PAS Robotics we maintain robots of any generation and condition —from an ABB S3/S4 to a KUKA KRC2 or a FANUC R-J3— without ruling them out by age.
Frequently asked questions
Is it worth maintaining an old robot?
In many cases yes: amortised, known and far cheaper than replacing. The key is good maintenance and access to parts.
Are there parts for discontinued robots?
Yes, via reconditioned and tested parts, the usual route for older generations.
When to replace?
When breakdowns are frequent and costly, productivity/safety is lacking, or the cost approaches that of a new unit.