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 liftcrane 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 liftcrane 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 perform assembly 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 slowly so as not to damage any parts, create any oil leaks, or compromise the efficiency of the equipment, etc. ・ 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

Code Part name Q'ty 1 Cover 1 2 O-ring 1 3 Thrust plate 1 4 Bushing 1 5 Shaft 1 6 Bushing 1 7 Floating seal 1 8 Roller 1 9 Collar 1 10 Plug 1 11 High-strength bolt 7 12 Loctite No. reqd.

Dimension diagram

Jig dimension diagram

A Bushing removal jig B Bushing press-fit jig (10) C Floating seal installation jig

Disassembly procedure [1] Clean the upper roller (2) with kerosene, remove the plug (1) from the cover, and drain the oil.

[2] Remove the bolts (3) from the upper roller (2) and remove the cover (4). Remove the O-ring (5) from the cover.

[3] Fasten the shaft (6) to a vise table and remove the bolts (3) and thrust plate (7).

[4] Pull out the upper roller from the shaft (6).

[5] Remove the floating seal (8) on the roller side.

[6] Use the press and removal jig (A) to remove the bushings (9) and (10) from the upper roller. •Do not disassembly the bushings as long as use has not yet been made impossible due to wear.

[7] Use a screwdriver or other tool to remove the floating seal (8) from the shaft (6) on the collar side. •When removing the floating seal, be careful not to scratch the collar (11) or shaft (6). •Normally, do not disassemble the collar (11).

Reassembly is extremely difficult.

Assembly procedure [1] Place parts in a rough cleaning container filled with kerosene to clean off any adhered matter that can form sharp points and cause scratches. •Immerse in kerosene until dust, grease, and other adhered matter comes off and floats to the surface. [2] Place parts in a finish cleaning container filled with kerosene and clean while gently moving the parts. After cleaning, wipe away the kerosene with a clean rag. •Place the parts in a location free of dust and moisture and use compressed air to dry the parts. After drying, coat parts with engine oil. [3] Use the jig (B) (4) and hammer to install the bushings (1) and (3) on the upper roller (2).

[4] Install the floating seal (5) on the upper roller (2) and apply oil to the surface (lip section) of the seal. •Use new floating seal.

[5] Install the floating seal (5) on the collar (6) and apply oil to the surface (lip section) of the seal. •Use new floating seal.

[6] Apply grease to the surface of the shaft (7) and install the upper roller (2) on the shaft.

[7] Install the thrust plate (8) on the shaft (7) using the hexagon bolts (9). •Apply grease to the inside of the thrust plate. •Apply Loctite to the bolts.

[8] Set the O-ring (11) with applied grease and install the cover (10) on the upper roller (2) with the hexagon bolts (9). •Use new O-ring. •Apply Loctite to the bolts.

[9] Use compressed air (12) to check for leaks in the assembly parts. Compressed air: 0.2 MPa

[10]Fill oil from the plug hole (13).

[11]Install the plug (14). •Clean the assembly parts and dry with compressed air.

This completes the assembly.