Incorrect J3 Axis Shaft O-Ring in NXB-GEN-713-001 Kit for R-50 Robot

Description

We are performing the scheduled 4000-hour preventative maintenance on one of our R-50 series robots. We ordered the standard NexBot Robotics 713-001 O-Ring And Gasket Kit for the job. Everything went smoothly until we reached the J3 axis. The J3 Axis Shaft O-Ring supplied in the kit (labeled as 45mm ID) is slightly too large for the groove on the axis shaft. It does not seat correctly and feels loose, which would certainly cause a grease leak under pressure. We have halted the maintenance procedure to avoid damaging the robot or installing an incorrect seal. We have double-checked the robot model (R-50) and the kit part number (NXB-GEN-713-001), and they should be compatible according to our documentation. The old o-ring is deformed from use and cannot be re-installed. We need guidance on whether we received a mispackaged kit or if there is an alternate part required for our specific robot.

Symptoms

• O-ring from kit does not seat properly in the J3 axis shaft groove.
• Supplied o-ring appears to have a larger inner diameter than the original part.
• Preventative maintenance procedure cannot be completed.
• Risk of lubricant leakage if incorrect seal is installed.

Resolution

Support analyst investigated the R-50 robot's serial number (R50-2023-11245) provided by the customer. It was determined that a running production change was implemented for R-50 models manufactured after Q3 2022. These newer models use a J3 axis shaft with a slightly smaller o-ring groove, requiring a 44.5mm ID o-ring instead of the 45mm ID o-ring included in the standard NXB-GEN-713-001 kit. The customer was informed of this production change. The correct replacement o-ring (Part # NXB-SEAL-J3-445) was shipped overnight. The customer was also advised to order kit variant NXB-GEN-713-001B for this and other newer R-50 units in the future to ensure compatibility.

Resolution Steps

1. 1. Confirmed the customer's R-50 robot serial number is within the range affected by the J3 axis design change.
2. 2. Explained the reason for the part incompatibility due to a mid-cycle engineering update on the robot hardware.
3. 3. Created a no-charge sales order for the correct J3 axis o-ring (Part # NXB-SEAL-J3-445) and arranged for expedited shipping.
4. 4. Provided the tracking number for the replacement part to the customer.
5. 5. Instructed the customer to complete the maintenance procedure using the correct o-ring upon its arrival.
6. 6. Updated the customer's account notes to specify the correct maintenance kit (NXB-GEN-713-001B) for their newer R-50 robots to prevent future issues.
7. 7. Closed the case after confirming the customer received the part and successfully returned the robot to service.