Assembly and Disassembly of Lower 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 sliding 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 •Wire clips •Pliers •Gear puller •Screwdriver •Gear oil (Mobile Gear Oil SHC320) •Specialty jigs •Pressing machine •Loctite •Special fiber cloth (Kimwipe) •Micrometer caliper •Caliper •Cylinder gauge

Configuration diagram

7 8

6

4

5

3

2

Dimension diagram

1

3

5

4

9

8

318 246 Part name Part number Q'ty 1 Roller KRA10370 1 2 Shaft KRA11260 1 3 Bushing KRA1197 2 4 Floating seal BHA1099 2 5 O-ring 1A-G60 BHA0863 2 6 Collar KRA1196 1 7 Plug with seal nylon KHJ0300 1 8 Wire clip KNA0180 2 9 Collar (without plug) KRA1595 1

Jig dimension diagram

9 1 2 3 4 5 6 7 8

A Bushing removal jig B Bushing press-fit jig 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. •Securely fasten so that the roller does not fall over.

[3] Remove the wire clip (4). Tap another wire (5) with the hammer (6) from the outside to push out the wire clip that is already in the roller. •Place the roller horizontally and secure it so it does not roll before doing this work. •The wire in the roller is very securely fixed, so prepare several wire clips. Also be sure to coat with lubricant.

1 Hexagon wrench 2 Plug 3 Oil pan 4 Wire clip 5 Wire 6 Hammer

[4] Use pliers (7) to remove the pushed out wire clip (4).

[5] Use a gear puller (8) to remove the collar (9). If the collar is difficult to remove, hook the collar on the bolt and catch the puller on that part. •If the collar has rusted or is difficult to remove due to an accumulation of debris, subject it to a shock, for example by hitting it with a hammer, to make it easier to move. •When hitting the collar with a hammer, be careful not to dent it.

[6] Check whether the surface of the floating seal (10) sliding against the removed collar has rusted or is damaged. Also check whether the O-ring (11) is twisted. •The O-ring cannot be reused. Always replace it with a new one.

4 Wire clip 7 Pliers 8 Gear puller 9 Collar 10 Floating seal 11 O-ring 12 Ring

[7] Remove the floating seal (10) on the roller.

As described in Step [6] above, check whether the surface of the floating seal sliding against the roller has rusted or is damaged. Also check whether the O-ring is twisted.

[8] Remove the O-ring (13) on the shaft (14). •The O-ring cannot be reused. Always replace it with a new one.

[9] Remove the shaft (14).

10 Floating seal 13 O-ring 14 Shaft

[10]As described in Step [7], remove the floating seal (10) on the opposite side.

[11]Use a micrometer caliper to measure the roller (with bushing) (17), collars (9) and (18), and shaft (14) for wear and deformation. Replace with new parts as necessary.

[12]When replacing a bushing, insert jig A (15) into the bushing (16), and use a cylindrical object (such as a shaft) (14) to push from the top.

The bushing comes off.

9 Collar 10 Floating seal 14 Shaft 15 Jig (A) 16 Bushing 17 Roller 18 Collar 19 Caliper 20 Micrometer caliper 21 Cylinder gauge

Assembly procedure [1] Clean all parts by immersing them in cleaning fluid. •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). Restraining from above using jig B (3), push in with the pressing machine (4).

Invert the roller and insert the bushing on the opposite side in the same manner.

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

[4] Use jig C (8) to push the floating seal (6) into the collar (7) and roller (5).

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

[6] Apply gear oil to the floating seals (6) on the collars (7) and (9).

5 Roller 6 Floating seal 7 Collar 8 Jig (C) 9 Collar

[7] Attach O-rings (11) to the shaft (10) and mount into the roller (5).

[8] Install the collars (7) and (9) on both sides.

[9] Attach the wire clip (12). •When attaching the wire clip, secure the roller main unit so that it does not roll.

5 Roller 7 Collar 9 Collar 10 Shaft 11 O-ring 12 Wire clip

[10]Turn the main unit and check that the roller rotates properly.

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

[12]Fill gear oil (125 cc) into the roller. Use a hexagon wrench (6 mm) (14) to tighten the plug (13) with the nylon seal applied. •Mobile Gear Oil SHC320 is recommended for use. •The plug tightening torque is 24.5 N•m. •To reuse a plug, wrap it with seal tape.

This completes the assembly.

13 Plug 14 Hexagon wrench