Using a grinder, grind down the ends of the two pins on the outer link (on the attachment side) until they are level with the outer plate.

Take care that the chain does not overheat (see Figures 6 and 7).

Particularly with Lambda Chain, work on the chain slowly so that the oil-impregnated bushes do not become too hot.

Fig. 6. Attachment chains

Fig. 7. Grinding the pin ends

(1)S Roller (A, SA, EP, GNK1 attachments)

Place the chain in the jaws of a vise with the attachment side facing up and gently tighten the vise to secure the chain (Figures 8 and 9).

Fig. 8. Setting Chain in Chain Vise

Fig. 9. Cross Section of Chain Set in Chain Vise

(2)S Roller (K, SK attachments), R Roller (K, SK attachments), Plastic R Roller, Poly Steel Chain (with attachments)

For these types, set the chain in a cradle (Figure 11-1).

Another method, used only with steel S rollers (Figure 11-2), is to set the pin to be removed on the edge of the chain vise.

Whichever method is used, support blocks should be placed under the chain on either side of the vise to ensure that the chain remains stable (Figure 10).

Any attachment can be cut using this method. However more force will be required to remove the pin as mentioned in “3. Pin below.

Fig. 10. Cradle and Support Blocks

Fig. 11-1. Cradle Cross Section

Fig. 11-2. Chain Vise Usage

(3)R-roller (A, SA, EP attachments )...This method cannot be used with plastic rollers.

Secure the non-attachment side plate of the chain in the vise and support the R rollers on the vise (Figure 13).

Ensure that the chain is supported on both sides of the vise (Figure 12).

Fig. 12. Chain Vise and Support Blocks

Fig. 13. Cross Section of Chain Set in Chain Vise

Cutting Chain When the Base Chain Roller Is an S Roller

For cutting Poly Steel chain with outboard rollers, refer to the below.

• (1)Determine the outer link to be cut and mark the link for identification.
• (2)Set the chain on a chain vise (sold separately) as shown above and shear off the rivets on the pin ends (two rivets on one side) using a hand grinder.
• (3)Remove the two pins using a pin with a diameter slightly smaller than the pin diameter of the chain (using a Tsubaki Punch or its equivalent). When the pins are pulled out a little, the two outboard rollers on the upper side can be removed. (The diagram above shows the outboard rollers being removed. )
• (4)Directly tap the pin with a small hammer until the end of the pin reaches the upper face of the outer plate to remove. Tap the two pins alternately to ensure they come off evenly.
  Use caution not to damage the outboard rollers on the right and left.
• (5)Tap and pull out the two pins using a punch until the outer plate on the upper side can be removed.

Cutting Chain When the Base Chain Roller Is an R Roller

• (1)Determine the outer link to be cut and mark the link for identification.
• (2)Shear off the rivets on the pin ends (four rivets) using a hand grinder so as to remove the four outboard rollers. In doing so, shear down to the washers with the grinder to remove the washers.
• (3)Remove the four outboard rollers. (Method ：Receive the outboard roller on the cradle, apply the punch on the pin end face, and tap the pin out until the washer is removed. Follow the same procedure to remove the washers on the other side. )
• (4)Set the chain on the cradle as shown above and remove the two pins by tapping the punch with a hammer. Prepare a cradle yourself as appropriate.
• (5)Follow steps (4) and (5) of "Cutting Chain When the Base Chain Roller Is an S Roller" on the above.
• (6)If outboard rollers are spaced every two or more links, the rivet parts to be sheared off will differ from those shown in the above diagram. (See the diagram below.) (See the diagram below. )

Cutting Poly Steel Chain with Outboard Rollers

・When the Outboard Rollers Are Arranged in a Staggered Installation

• (1)Determine the outer link to be cut and mark the link for identification.
• (2)Although the chain can be set in a chain vise in the same manner as shown in "Cutting Chain When the Base Chain Roller Is an S Roller" on the above, this setting damages the chain because the inner link is made of engineering plastic. For this reason this cutting method cannot be used.
• (3)Lightly tighten the washer on the pin end with a chain vise, as shown above. Since no rivet is provided on the pin end on this chain, proceed to cutting the chain.
• (4)Use a pin with a diameter slightly smaller than the pin diameter of the chain (using a Tsubaki Punch or its equivalent), tap the punch lightly with a hammer, and pull out the pin of the chain gradually (see the above diagram. )When the pin is removed from the upper outer plate as shown above, stop tapping the pin.
• (5)When pins (a) and (b) are pulled out in the same procedure, the chain can be cut. The diagram above shows the state whereby pin (a) has been pulled out to the specified position and pin (b) has already been pulled out.
• (6)Discard the cut outer links (shown below).
  

・When the Outboard Rollers Are Arranged in a Crosswise Installation

• (1)Determine the outer link to be cut and mark the link for identification.
• (2)Although the chain can be set in a chain vise in the same manner as shown in "Cutting Chain When the Base Chain Roller Is an S Roller" on the above, this setting damages the chain because the inner link is made of engineering plastic. For this reason this cutting method cannot be used.
• (3)Support outboard roller "A" on the upper side with a chain vise as shown above and lightly tighten the chain vise. Bring the outer link to be cut to the end of the chain vise, as shown above.
• (4)Apply the punch to the pin end of outboard roller "A" and lightly tap the punch with a light hammer. Outboard roller "A" will be removed as shown below.
  
• (5)Turn the chain upside down and remove outboard roller "B" by following the same procedure for removing outboard roller "A" .
• (6)Set the chain after removing outboard rollers "A" and "B" on the cradle as shown below, tap the punch lightly with a hammer, and remove the two pins. Pull out the pins up to a position where the upper outer link is removed. (Prepare a cradle yourself as appropriate. )
  

Check that the spring clip is securely attached. Failure to install the spring clip or improper installation may result in an accident.

• 1)Spring clips are used to secure the connecting link of chain sizes smaller than RF2060 and RS60. Insert the pins of the connecting link into the bushes of the free inner links, place the link plate over the pin ends, and slide the spring clip over the ends of the pins so that the slot and the fingers of the clip engage the grooves securely (Figures 18 and 19).
• 2)Pay careful attention to ensure that the fingers of the spring clip are not spread too wide. If the spring clip does not fit securely, it could become detached without warning, leading to an accident (Figures 19 and 20).
  

  Fig. 18. Slide Spring Clip Over Grooves in Pin Ends

  

  Fig. 19. Use a Pair of Pliers to Secure Spring Clip

  

  Fig. 20. Spring Clip Installed Correctly

• 3)In general, the spring clip should be installed in the direction opposite to chain travel, as shown in the drawing below (Figure 21).
  

  Fig. 21.Direction in which the clip is installed

Securely install the cotter pins in the holes provided on the ends of the pins. Failure to install the cotter pins or improper installation may result in an accident.

• 1)After the cotter pin has been fully inserted into the hole on the end of the pin, open the legs of the cotter pin to an angle of around 60 (Figure 22). Do not re-use cotter pins. Do not use commercially available cotter pins.
  

  Fig. 22.Open Legs of Cotter Pin

• 2)How to Open the Legs of the Cotter Pin
  

  Fig. 23.

  • (1)Insert the cotter pin into the cotter pin hole.
  • (2)Use a pin that is somewhat larger in diameter than the cotter pin to lightly tap the head of the cotter pin. The legs of the pin will open slightly.
    

    Fig. 24.

  • (3)Insert the blade of a flathead screwdriver at the point where the legs of the cotter pin have opened slightly.
    

    Fig. 25.

    ⚠ Notes

    Perform this operation with extreme care! If the end of the screwdriver slips, it could puncture the hand or cause other injury.

  • (4)Insert the blade of the flathead screwdriver at an angle and move the screwdriver back and forth to open the legs of the cotter pin.
  • (5)Press down the head of the cotter pin tightly so that the cotter pin will not disengage from the cotter pin hole.
  • (6)Bend the cotter pin legs to the 60-degree angle mentioned on the above.

1) Connecting Using a Spring Clip (RF2060 or smaller )

• (1)Pass the two pins of the connecting link through the bushes of the inner link and then through the holes of the connecting plate.
  
• (2)Fit the spring clip securely into the pin groove.
  

2) Connecting Using a Cotter Pin (for RF2080 )

• (1)Pass the two pins of the connecting link through the bushes of the inner link and then through the holes of the connecting plate.
• (2)Pass the cotter pin through the hole of the pin and open the legs of the cotter pin to an angle of about 60 degrees.
  

1) When the Outboard Rollers Are Arranged in a Staggered Installation

• (1)Pass the two pins of the connecting link through the holes of the inner link and then through the slip-fit connecting plate.
• (2)Insert a cotter pin through each pin and open the legs of the cotter pin to an angle of about 60 degrees.

2) When the Outboard Rollers Are Arranged in a Crosswise Installation

• (1)Pass the two pins of the connecting link through the holes of the inner link and then through the slip-fit connecting plate.
• (2)When installing outboard rollers on both sides of a pin as shown above, pass the pin through the outboard rollers and washer, and attach cotter pins in two places. Open the legs of the cotter pins to an angle of about 60 degrees.