Assembly and Disassembly of Take-up 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 assemble in a clean location. ・ When assembling floating seals, O-rings, and other 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. ・ The take-up roller is a heavy object and requires at least 2 workers to handle. 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 •Screwdriver •Engine oil (Shell Rimula Oil #30) •Specialty jigs •Pressing machine •Special fiber cloth (Kimwipe) •Seal tape •Oil pan (drip pan) •Water container for inspection

Configuration diagram

Dimension diagram

Jig dimension diagram

135+0 -0.2

125+0 -0.2 100

20 5 40

10 175 127

30

218

194 Code Part name 1 Bracket (right) 2 O-ring 3 Take-up roller 4 Bushing 5 Floating seal 6 Bracket (left) 7 Shaft 8 Pin 9 Plug

X

214 207.5 C0.5 C0.5 0.5

18

C3

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

Disassembly procedure [1] Clean the take-up roller (1) with kerosene. [2] Remove the plug (3) from the left and right brackets (2) and drain the oil. •The plug is coated with seal nylon, which comes off when the plug is removed. Seal tape is necessary for reusing. •It may take a few hours to completely empty the oil. •Place an oil pan underneath to catch the oil.

[3] Remove the pin (4) from the bracket (left) (2), and use a gear puller or other tool to remove the bracket from the shaft (5). •Remove only one side. •Securely fasten the roller before doing this work. •As it is very securely fixed, apply lubricant before beginning work. •If the hub 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 it with a hammer, be careful not to dent it. [4] After removing the O-ring (6) from the shaft (5), pull the shaft out along with the bracket (right). •The O-ring cannot be reused. Replace it with new part.

[5] After removing the pin (7) from the bracket (right) (2), pull the bracket (right) (2) out from the shaft (5), and remove the O-ring (6).

[6] Remove the floating seal (8) from the bracket (right) (2). •Remove at the bracket (left) in the same way.

[7] Remove the floating seal (8) from the take-up roller (1).

[8] Use the removal jig (A) and press to remove the bushings (9) from the take-up roller (1).

Assembly procedure [1] Place parts in a rough cleaning container filled with kerosene (cleaning fluid) 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 (cleaning fluid) and clean while gently moving the parts. After cleaning, air blow the parts and 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) (3) and hammer (4) (or pressing machine) to install the bushings (2) in the takeup roller (1).

[4] Coat the floating seal with grease and use jig (C) to install the floating seal (5) in the take-up roller (1).

[5] Coat the floating seal (5) with grease and use jig (C) to install the floating seal (5) on the bracket (left) (6). •Use new floating seal (5).

[6] After installing the O-ring (7) with applied grease to one side of the shaft (8), install the shaft in the bracket (left) (6) and fasten it with the pin (9). •Use new pin and O-ring.

[7] Apply grease to the surface of the shaft and install the shaft (8) in the take-up roller (1).

[8] Set the O-ring (7) with applied grease onto the shaft (8), install the bracket (left) (6), and fasten with the pin (9).

[9] Use compressed air to check for leaks in the assembly parts.

Compressed air pressure: 0.2 MPa

[10]Fill oil (about 780 cc) from the plug hole (10). •The roller main unit can be very unstable, so give consideration to securing it.

[11]Install the plug (11). •Clean the assembly parts and dry with compressed air. •To reuse a plug, wrap it with seal tape.