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📦 Video 1 · §3-4 Operation
🔧 Video 2 · Appendix D Tool
14mm
Max Inlet Wire
3mm
Min Outlet Wire
6
TC Rolls / Cassette
12
32008 Bearings
🏗️ Dual-Compartment Architecture
IN compartment receives wire · OUT compartment delivers formed wire · Synchronized adjustment via central nut
📥 INPUT
IN Compartment
Wire enters here at 14 mm max
3Arm Blocks
3Roll Holders
3TC Rolls
→
📤 OUTPUT
OUT Compartment
Formed wire exits at 3 mm min
3Arm Blocks
3Roll Holders
3TC Rolls
📋 Complete Specifications
Source: ASIANMAC Roll Cassette Instruction Manual v2024-R5
| Wire Material | Low-carbon wire (smooth or ribbed) |
|---|---|
| Maximum Inlet Diameter | 14 mm |
| Minimum Outlet Diameter | 3 mm |
| Standard TC Roll Dimensions |
OD125 × ID82 × T15 (paired with IS82 × T15 holder, CP25 or CP26) OD125 × ID82 × T20 (paired with IS82 × T20 holder, CP25 or CP26) |
| Roll Holder Bearings | 32008 Taper Roller Bearing · 2 per holder · 12 per full cassette |
| Cooling Pin Tolerance (Critical) |
CP25: shank diameter 24.96 – 24.98 mm CP26: shank diameter 25.96 – 25.98 mm Out of tolerance → must replace |
| Greasing Standard | MILLENIUM Grease · NLGI 1.5-2 · Drop point >300°C · Range -25 to +180°C Re-grease every 8 hours with Q = (D × B) / 200 grams → Open interactive calculator |
| Documentation | 17-page manual (am_rcinstructionmanual_2024-R5) with parts diagrams, operation sequences, preventive maintenance, exploded views |
🎬 Live Demonstration · Manual v2024-R5
Watch This Cassette In Action
Two videos from ASIANMAC's Selangor factory — exactly the procedures documented in the manual sections above.
Roll Cassette · Complete Assembly SOP
Full standard operating procedure: opening cassette → installing Roll Holders in Arm Blocks → cooling pin sequence → final assembly check. Matches Manual §3 Working Principle and §4 Operation Instructions.
▶ Open in Dropbox (HD) →TC Roll Holder · Knock-Free Assembly System
The proprietary maintenance tool from Manual Appendix D. Demonstrates "knock-free operation" — bearings come out without hammer impact, ensuring zero damage to seats and races. The reason maintenance time drops 75%.
▶ Open in Dropbox (HD) →
📘 Both videos directly demonstrate procedures documented in the ASIANMAC Roll Cassette Instruction Manual v2024-R5 (17 pages, available on request).
🔩 Parts Catalog
Complete inventory per compartment from manual diagrams
a) Locking System (7 part types)
Bush Washer
× 4
Spring Washer
× 4
Hexagon Bolt M22 × 2.0
× 4
Supporting Shaft (Upper)
× 2
Supporting Shaft (Lower)
× 2
Adjustment Nut
× 1
M16 Screw Hole
× 4
b) Inner Compartment Parts (12 part types per compartment)
Greasing Block
× 1
Greasing Nipple
× 3
Greasing Hose
× 3
Side Casing
× 1
Eye Bolt
× 2
Arm Block
× 3
Ejector Pin 16 × L100mm
× 3
L-Water Fitting
× 3
Cooling Pin
× 3
Rubber Water Hose
× 4
Cam Shaft Jaw
× 1
Cam Shaft Jaw Locknut
× 1
c) Roll Holder Internal (7 part types)
Roll Holder Locknut
× 1
Circlips B70
× 2
Side Cover
× 2
Side Bush
× 2
⭐ 32008 Taper Roller Bearing
× 2
Center Bush
× 1
Roll Holder Core
× 1
⚙️ Working Principle
| Tighten (clockwise) | Adjustment nut closes the 3-arm-block assembly → narrows gap between TC rolls → wire deformation occurs |
|---|---|
| Loosen (anticlockwise) | Adjustment nut opens the compartment → releases pressure on working wire |
| Adjustment Tool | Use designated "lock nut adjustment spanner" (manual adjustment only) |
🔴 Extreme caution when gap < 1 mm: TC rolls can crash on each other → catastrophic damage. Never force the adjustment in this range.
🛡️ Preventive Maintenance Standards
| Cassette Main Compartments | Keep clean from steel oxide scales + lubricant powders + grease build-up. Use maintenance cloths or air gun in enclosed area. |
|---|---|
| Cooling Pin Diameter Check | Weekly · ensure CP25 (24.96-24.98 mm) or CP26 (25.96-25.98 mm) within tolerance · replace if out |
| Grease Nipple Cleaning | Monthly · clean by immersing in ethanol · replace worn units for clog-free operation |
| Grease Hose Replacement | Change immediately when clogged with hardened compound |
| Roll Holder Bearings | Use only genuine 32008 Taper Roller Bearings · "knock-free" removal only · visual inspection on every change |
| Re-Greasing Schedule |
Every 8 hours of cold-rolling operation Quantity: Q (g) = (D × B) / 200 with Ndn speed correction Grease: MILLENIUM (NLGI 1.5-2) |
⚠️ Critical Warnings
🔴 Wrong Roll Holder Orientation: Installation with wrong direction causes the locknut to loosen during operation → TC roll derails from aligned position → disastrous damages. Always align top (dark grey) facing "<" symbol on the base.
🔴 DO NOT Use Water Jet to spray-clean the roll cassette. Water flushes grease away from the mechanism → rust problems occur on cassette components.
🔴 DO NOT Use Hammer/Impact when removing bearings from TC Roll Holders. Always apply "knock-free" operation practice with specifically designed service & maintenance system.
🟡 Genuine Parts Only: Only use genuine ASIANMAC precision parts to maintain optimum Roll Holder performance. Counterfeit bearings cause premature failure and safety risks.
🟡 Grease Specification Matters: Use only MILLENIUM-equivalent (NLGI 1.5-2, drop point >300°C). Wrong grease → bearing seizure → unplanned downtime.
🤝 The UKO + ASIANMAC Golden Match
ASIANMAC Cassette's standard TC Roll dimension OD125 × ID82 × T15/T20 matches exactly with UKO PR8 carbide rolls (YG15 / YG16C / UK50 grades). Single supplier = single after-sales contact.
📞 Inquire about Roll Cassettes
Order, technical questions, spare parts, on-site training — talk to ASIANMAC directly.