Assembly and Disassembly of Upper Roller

Caution ・ To ensure safe operations, wear protective devices before beginning work and follow all precautions. ・ When removing devices or positioning devices at the time of installation, use a removal jig and a hammer or steel rod. ・ Follow the precautions below when suspending the load. ・ The crane must be operated by a qualified operator. ・ Do not stand or pass under the suspended load. ・ Check the weight of the roller to determine whether it can be carried by hand or whether a crane must be used. ・ Fix the roller to a level surface so it does not roll. ・ Be sure to repair any parts damaged during disassembly, and prepare replacement parts in advance. ・ If any parts are significantly rusted or dirty, clean them before disassembling. ・ Any foreign matter entering the equipment during assembly can create a malfunction.

Therefore, after thoroughly cleaning the equipment with cleaning oil, air blow the equipment, and assemble in a clean location. ・ When assembling touching parts, be sure to coat them with new hydraulic oil. ・ As a rule, replace all O-rings and other seal parts with new parts. <General cautions> ・ Be careful not to drop precision parts or let bump them with other parts during work. ・ Do not forcefully open or hit parts in an effort to speed up operations. Pay careful attention and proceed with caution so as not to damage any parts, create any oil leaks, or compromise the efficiency of the equipment. ・ Disassembled parts can easily rust or collect dust. Therefore, immediately after disassembling parts, take precautions to prevent the parts from rusting or collecting dust.

Items to prepare •Hexagon wrench (6 mm) •Hammer •Wrenches (13 mm, 17 mm) •Box wrench (17 mm) •Screwdriver •Engine oil (Shell Rimula Oil #30) •Specialty jigs •Pressing machine •Loctite 262 •Special fiber cloth (Kimwipe) •Marking pen •Micrometer caliper •Caliper

Configuration diagram

13

12

10

11

9

Dimension diagram

1 2

3

4

5

62

Jig dimension diagram

8

7

1

5

3

4

6

114.5 Part name Part number Q'ty 1 High strength bolt M10X16 102R010Y016N 2 2 Loctite #262 KRC5007 Q'ty reqd. 3 Cover (bolt stopper) KRA1719 1 4 Plug with seal nylon KHJ0300 1 5 O-ring UHA0049 1 6 High strength bolt M8X25 102R008 3 7 Thrust plate KRA1123 1 8 Shaft KRA1252 1 9 Bushing KRA1248 1 10 Bushing KRA1249 1 11 Roller KRA1718 1 12 Floating seal KBA0783 1 13 Bracket KRA1305 1

65

12

13 11.5

7 8 9 10 11

A Bushing removal jig B1 Bushing press-fit jig (10) B2 Bushing press-fit jig (9) C Floating seal installation jig

Disassembly procedure [1] Stand the roller vertically and use a hexagon wrench (6 mm) (1) to remove the plug (2). •The plug is coated with seal nylon, which comes off when the plug is removed. To reuse the plug, be sure to use seal tape.

[2] Face down the part of the roller from which the plug was removed and empty the oil from within the roller. •It may take a few hours to completely empty the roller of oil. •Place an oil pan (3) under the roller to catch the oil.

[3] Use a wrench (13 mm) to remove the 3 bolts (4) from the cover (5).

1 Hexagon wrench 2 Plug 3 Oil pan 4 Bolt 5 Cover

[4] Remove the cover (5).

If the cover is difficult to remove, it is possible to use an adapter to apply compressed air or to pry it open by inserting a flathead screwdriver into either end of the cover. •When using compressed air, be careful of flying parts.

[5] Use a box wrench (17 mm) to remove the 2 bolts (7) inside the roller, and then remove the thrust plate (8).

[6] Lift the roller (9) and the shaft (10) comes off.

5 Cover 6 Air hose 7 Bolt 8 Thrust plate 9 Roller 10 Shaft

[7] Remove the floating seal (11) on the roller.

Check whether the surface of the floating seal sliding against the roller has rusted or is damaged. Also check whether the O-ring (12) is twisted.

[8] Remove the floating seal (11) on the shaft (10). •The shaft and bracket (14) cannot be removed.

[9] Remove the O-ring (15) on the cover (16) side. •Check whether the O-ring is twisted. If it is twisted, replace it with a new O-ring.

9 Roller 10 Shaft 11 Floating seal 12 O-ring 13 Ring 14 Bracket 15 O-ring 16 Cover

[10]Use a micrometer caliper to measure the roller (with bushing) (9), bracket (14), and shaft (10) for wear and deformation.

Replace with new parts as necessary.

[11]When replacing a bushing (22) and (23), use jig A (21) to restrain it from the side where the shaft (10) was removed and press it out with a pressing machine (20).

9 Roller 10 Shaft 14 Bracket 17 Caliper 18 Micrometer caliper 19 Cylinder gauge 20 Pressing machine 21 Jig (A) 22 Bushing [10] 23 Bushing [9]

Assembly procedure [1] Clean all parts. •Find a clean location. •Place a rubber plate or cloth on the work surface so as not to damage the parts.

[2] After cleaning the parts, air blow them to remove any remaining cleaning fluid or debris.

[3] If the bushing (2) was removed during disassembly, put it into the roller (5). Face up the thrust plate installation side, restrain from above using jig B2 (3), and push in with the pressing machine (4).

1 Cleaning fluid 2 Bushing 3 Jig (B2) 4 Pressing machine 5 Roller

[4] Invert the roller (5) and insert the bushing (6). Restraining from above using jig B1 (7), push in with the pressing machine (4).

Push in all the way to the position where jig

B1 stops.

[5] Insert the floating seal (8) into the roller (5) and bracket (10). Use jig C (9) to press the floating seal into position.

[6] Use a special fiber cloth to wipe the surfaces of the floating seals so as to increase adhesion and prevent dust from entering.

4 Pressing machine 5 Roller 6 Bushing 7 Jig (B1) 8 Floating seal 9 Jig (C) 10 Bracket

[7] Apply hydraulic oil to the roller (5).

[8] Attach the shaft (11) to the roller (5).

[9] Use a special fiber cloth to thoroughly wipe the thrust plate (12) to prevent any dust or scratches.

5 Roller 11 Shaft 12 Thrust plate

[10]Use a box wrench (17 mm) to fasten the thrust plate (12) with the 2 bolts (13).

Degrease the bolts well, apply Loctite (14) to the bolt openings, and tighten the bolts.

After tightening the bolts, mark them (15). •The bolt tightening torque is 62.8 - 72.6

N•m.

[11]Use a wrench (13 mm) to fasten the cover (18) with the 3 bolts (17). Degrease the bolts, apply Loctite (14) to the bolt openings, and tighten the bolts. After tightening the bolts, mark them (16). •The bolt tightening torque is 31.4 - 37.2

N•m.

[12]Rotate the roller in the direction of the arrow and check that it rotates smoothly.

12 Thrust plate 13 Bolt 14 Loctite 15 Marking 16 Marking 17 Bolt 18 Cover

[13]Inject compressed air (0.2 MPa) from the oil fill port and immerse in water to check that there are no leaks.

[14]Fill engine oil (50 - 55 cc) into the roller.

After filling the engine oil, use a hexagon wrench (20) to tighten the plug (21) (coated with seal nylon). After tightening the bolts, mark them (19). •To reuse a plug, wrap it with seal tape.

This completes the assembly.

19 Marking 20 Hexagon wrench 21 Plug