Mechanical Assembly Procedure - Farr KT5500 Technical Manual

M
aInTEnanCE
Mechanical Assembly Procedure (Continued):
5. Install support roller assemblies in the locations exposed by the opening in the rotary gear. Continue to rotate the rotary gear,
installing support roller assemblies in the rotary gear opening as it is rotated. Finish with the rotary gear aligned with the opening
in the bottom plate.
6. Press pinion bearing (PN 02-0007) into bottom pinion bearing cap (PN 997-D15-89), and install bearing cap into bottom plate
of tong using four 1/2" UNC x 1-1/4" hex cap screws and four 1/2" lock washers. ASSEMBLY NOTE: Do not neglect to install
the clutch bearing cap spacer (PN 1400-89A) between the bearing cap and the bottom plate of the tong.
7. Press bottom clutch bearing (PN 02-0004) into clutch bearing cap (PN 997-D11-54), and install bearing cap into bottom plate
of tong using four 3/8" UNC x 1-1/4" hex cap screwsand four lock washers. ASSEMBLY NOTE: Do not neglect to install the
clutch bearing cap spacer (PN 1400-54A) between the bearing cap and the bottom plate of the tong.
8. Install a retainer clip (PN 02-0009) into all three idler gears (PN 997-A2-119). Press an idler bearing (PN 02-0011) into each
gear and secure with a second retainer clip.
9. Lightly grease the larger circumference of the two rotary idler shafts (PN 997-D19-117) and slide them through two bearing and
gear assemblies, centering the gear on the shaft.
10. Slide two bearing seals (PN 02-0010) over each end of the idler shafts and press against the retainer clips. See the exploded
view of the rotary idler assembly on pp. 5.8 - 5.9 for correct orientation of the bearing seals.
11. Slide a bearing spacer (PN 997-D20-121) over each end of the rotary idler shafts.
12. Place each rotary idler assembly through the bottom plate, ensuring the ends of the shafts with the threaded holes for the grease
fittings are pointed upward.
13. Place an idler pad (PN 1400-125) over the bottom side of each rotary idler shaft, and secure each with a 1-1/2" UNF nylock nut.
14. Place high pinion gear (PN 997-A4-87) shoulder side down over the lower bearing and bearing cap, centering as best as able.
15. Install pinion gear shaft (PN 997-A7-86) into the spline of the bottom pinion gear, and the lower pinion bearing.
16. Slide 4 needle bearings (PN 02-0003) onto clutch shaft (PN 997-A8-50), two on either side of the center gear. Press bearings
firmly against centre gear.
17. Slide high clutch gear (PN 997-A1-51) over the bottom end of the clutch shaft, and seat gear on the needle bearings, ensuring
the smaller diameter on the high clutch gear is oriented toward the center gear on the clutch shaft. Place lower end of clutch
shaft into the lower clutch bearing that has been pre-mounted in the lower body plate, and mesh the high clutch gear with the
high pinion gear.
18. Install shifting collar (PN 997-A9-62) over the top of the clutch shaft and mesh with the center clutch gear.
19. Slide the shifting fork (PN 997-D13-72) over the end of the shifting shaft (PN 1400-71), and secure the fork in place with a 5/8"
UNF hex jam nut followed by a 5/8" UNF regular hex nut. Place the end of the shifting shaft in the lower shifter bushing (typically
welded to the bottom plate) and mesh the shifting fork with the shifting collar.
20. Slip the low clutch gear (PN 997-A1-52) over the top of the clutch shaft and seat on remaining two needle bearings, ensuring
the smaller diameter on the high clutch gear is oriented toward the center gear on the clutch shaft.
21. Slide the pinion idler half-shaft (PN 997-D17-105) through the remaining idler gear assembly. Place a bearing seal over the end
of the half-shaft, and secure the gear assembly to the half-shaft with a retainer ring (PN 02-0008).
22. Place the end of the pinion idler half-shaft through the bottom plate and mesh the pinion idler gear with the two rotary idler
gears. Secure the half-shaft to the bottom plate with the half-moon idler pad (PN 1400-109), three 5/8" UNC x 2-1/4" hex bolts
and 5/8" lock washers, and a 1-1/2" UNF hex nylock nut.
23. Install the low pinion gear (PN 997-A5-88) shoulder side up over the top of the pinion gear shaft, meshing with the low clutch
gear.
24. Carefully remove all support roller shafts, using caution not to shift the position of the installed support roller assemblies or
to damage the threads on the end of the shafts.
25. Insert three 3/8" x 1-1/4" hardened production ground dowel pins into the top edge of the side body, one in the rear center, and
one in the untapped holes on either side of the door opening.
26. Position the top plate in its proper location. Use caution not to damage threads when aligning the top plate with the rotary idler
and support roller shafts. Ensure the top of the shifting shaft is smoothly guided through the associated hole in the top plate.
ENSURE THE TOP PLATE REMAINS PARALLEL TO THE SIDE BODY TO AVOID BINDING ON THE
DOWEL PINS.
27. Use a rubber or wooden mallet to evenly tap the circumference of the top plate until it is flush with the side body.
KT5500 5-
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