Installation Guide: NexBot Robotics 762-001 Joint Overhaul Kit for R-50/R-100 Series

1. Confirm the robot is in a designated maintenance zone and powered down using Lockout/Tagout (LOTO) procedures.
2. Back up all robot controller programs, system parameters, and mastering data to an external device.
3. Carefully move the robot arm to the prescribed maintenance position for J2/J3 access, ensuring it is mechanically secured against gravity drops.
4. Unpack the NXB-KIT-762-001 and verify all components listed on the packing slip are present and free from shipping damage.
5. Clean the exterior of the target joint housings (J2 and J3) to prevent contaminants from entering during disassembly.
6. Ensure the work area is clean, well-lit, and has adequate space for laying out disassembled components in order.

Step 1: Step 1: Disconnect Power and Remove Axis Covers

After confirming LOTO is active, disconnect motor power and encoder cables from the J2/J3 motors. Carefully remove the plastic or metal cosmetic covers over the joint housings, keeping track of all fasteners for reassembly.

Step 2: Step 2: Disassemble Joint Housing

Systematically unbolt and remove the primary joint housing or reducer mounting plate. Be prepared to support the weight of attached linkages as the joint is separated. Note the orientation of all parts as they are removed.

Step 3: Step 3: Remove Old Bearings and Seals

Using the appropriate bearing puller and snap ring pliers, remove the main cross-roller bearing, harmonic drive wave generator bearing, and any associated oil seals. Place old components aside for proper disposal and do not mix them with new kit components.

Step 4: Step 4: Clean and Inspect Mating Surfaces

Thoroughly clean all internal housing surfaces and shafts with an approved solvent and lint-free wipes. Inspect the cleaned surfaces for any scoring, burrs, or cracks that could compromise the overhaul. Report any damage to a supervisor before proceeding.

Step 5: Step 5: Install New Seals and Bearings from Kit

Carefully install the new oil seals from the kit, ensuring they are square in their bores and the sealing lips face the correct direction. Using a bearing press or by carefully tapping with a soft-faced mallet on a correctly sized driver, install the new bearings, ensuring they are fully and squarely seated.

Step 6: Step 6: Reassemble Joint Housing

Carefully reassemble the joint components in reverse order of disassembly. Apply a thread-locking compound to critical bolts as specified in the R-50/R-100 service manual and tighten them in a star pattern to the specified torque value.

Step 7: Step 7: Apply Lubrication

Using a clean grease gun, apply the grease supplied in the NXB-KIT-762-001 to the designated grease fittings. Pump grease slowly until a small amount is seen purging from the relief vents to ensure the cavity is full without over-pressurizing the seals.

Step 8: Step 8: Reinstall Covers and Reconnect Cables

Reconnect the motor power and encoder cables, ensuring connectors are fully seated and locked. Reinstall all cosmetic and protective covers removed in Step 1.