Aerial Platform with Spec No.: AT-146-3A-00090

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2 Supplement AT-146TE-3/S1-1E-2 Aerial Platform with Spec No.: AT-146-3A This document is a supplement to the existing service manual with Publication No.: AT-146TE-3/S1-1E. The specifications of this aerial platform with spec. No. AT-146-3A are not included in the existing Service manual. The aerial platform with spec. No. AT-146-3A differs from with spec. No. AT in the items listed below. For the items listed below, see this document. For the other items, refer to the AT-146TE-3/S1-1E. Contents of this supplement (Sections different from those in the existing manual) The contents of this manual are as follows: December 2014 TADANO LTD. Section Page Chapter B B-1 Hydraulic Pump (for PTO) P.2 Chapter C C-1 Pilot Check Valve (for Jack Cylinder) P.4 Chapter E E-6 Relief Valve (for Leveling Circuit) P.5 Chapter F F-1 Winch P.6 Chapter H H-1 Length Detector (for Boom) P.17 Chapter J J-1 Bucket P.23 J-2 Hydraulic motor (for Bucket Swing) P.29 1

3 B-1 B-1 Hydraulic Pump (for PTO) B-1 Hydraulic Pump (for PTO) There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations. 1. Structure 1. Retaining ring 5. Body 9. Front cover 13. Rear cover 2. Oil seal 6. Washer 10. Bush 3. Gasket 7. Hexagon socket head bolt 11. Driven gear 4. Side plate 8. Drive gear 12. Gasket Thread size and tightening torque Sign/port Thread size Tightening torque N-m kgf-m Suction port G Discharge port G1/ Hexagon socket M Fixing bolt M W E

4 B-1. Hydraulic Pump (for PTO) B Removal and installation When replacing the pump, make sure that the revolving direction of the new pump is same as the old ones. (The revolving direction stamped on the rear cover of the pump assumes the view from the end of the revolution axis.) 3.2 Replacing the gaskets and backup strip 1. Remove the hexagon socket head bolt [7], and take away the front cover [9]. 2. Detach the gaskets [3, 12] from and backup strip [13] from the front cover [9] and the side plate [4]. 3. Install new gaskets [3, 12] and a backup strip. Then attach the front cover and fix it using a hexagon socket head bolt [7]. 4. Replace the gaskets and backup strip on the rear cover according to the above IW Disassembly and assembly CAUTION Do not touch the areas other than specified in this section. Never move the gears inserted in the body. If the gear is pulled out of the body, the mesh position of the teeth will change and the pump may fail to work sufficiently. The cover and the body are made of aluminium alloy and easy to be scratched. Handle them with care. Do not leave any oil or grease on the mating faces of the cover and body. 4. Precautions after replacing the pump 1. When starting the pump, perform the inching operation. Do not operate it at a high speed or high pressure. When the pump starts, air bubbles exist in the pipings. Bleed the pipings completely. Before bleeding is complete, operate the pump at a low pressure (if possible, with no load) to run in the pump. 2. After the run-in is completed, increase the load gradually up to the one for actual operation. Before starting actual operation, check for any abnormalities such as oil temperature. 3.1 Replacing the oil seal 1. Remove the hexagon socket head bolt [7], and take away the front cover [9]. 2. Detach the retaining ring [1] from the front cover [9], and remove the oil seal [2]. 3. Install a new oil seal in the front cover [9] and fix it using a retaining ring [1]. 4. Pack grease (COSMOGREASE DYNAMAX No.3 or equivalent), between the lips of oil seal [2]. 5. Wind a tape around the splines of the drive gear [8] to prevent damage to the lip of the oil seal [2]. Then attach the front cover [9] and fix it using a hexagon socket head bolt [7] W E

5 C-1. Pilot Check Valve (for Jack Cylinder) C-1. C-1 Pilot Check Valve (for Jack Cylinder) There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations. 1. Structure General view Hydraulic symbol A A B B C C D IW D IW Valve Body 2. Cap seal 3. Piston Sleeve 6. O-ring 7. Backup ring 8. Check valve 9. O-ring 10. Spring 11. Plug 12. O-ring Thread size and tightening torque Sign / port Thread size Tightening torque N-m kgf-m ft-lbf A G1/ B G1/ Mounting M W

6 E-4. Relief Valve (for Leveling Circuit) E-4. E-4 Relief Valve (for Leveling Circuit) There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations. 1. Construction Hydraulic symbol 1. Body 2. Guide 3. Poppet 4. Plug 5. O-ring 6. Spring 7. Spacer 8. Plug 9. Plug 10. O-ring 11. Poppet 12. Spring 13. Sheet Thread size and tightening torque Sign / port Thread size Tightening torque N-m kgf-m Plug [4] M Plug [9] G3/8 49±5 5.0±0.5 P1, P2, T G1/4 29.4±3 3.0± W E

7 F-1 F-1 Winch F-1 Winch There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations. 1. Winch Assy 1.1 General view W E

8 F-1 F-1 Winch 1.2 Main body Hydraulic symbol Main unit W E

9 F-1 F-1 Winch Drum rotational direction and oil flow direction Rotational direction (viewed from the control valve) Inlet port Outlet port Counterclockwise (hoist-up) B A Clockwise (hoist-down) A B W E

10 F-1 F-1 Winch W E

11 F-1 F-1 Winch 1. Drum 19. Hexagon socket head bolt 106. Shoe (*5) 125. Stopper 2. Spindle (*1) 20. Bearing 107. Retainer plate 126. Spring 3. Flange (*1) 21. Bearing 108. Thrust ball 127. Spring 4. RV gear (*2) 22. Bearing (*2) 109. Timing plate 128. Orifice plug 5. Shaft 23. Bearing (*2) 110. Washer 129. Plug 6. Input gear 24. Retaining ring 112. Piston 130. Valve 7. Spur gear (*3) 25. Retaining ring 113. Spring 131. Spring Retaining ring 114. Spring 132. Oil seal 9. Crank shaft (*2) 27. O-ring 115. Friction disc 133. Bearing 10. Bush 30. O-ring 116. Mating disc 134. Bearing 12. Retaining ring 33. Plug 118. O-ring 135. Parallel pin 13. Sleeve 34. Orifice 119. O-ring 136. Parallel pin 14. Distance piece 101. Rear flange (*4) 120. O-ring 137. Needle roller 15. Oil seal 102. Shaft 121. O-ring 138. Retaining ring 16. Oil seal 103. Thrust plate 122. Spool (*4) 139. Hexagon socket head bolt 17. Pin 104. Cylinder block 123. Plug 143. Retaining ring 18. Parallel pin 105. Piston (*5) 124. Stopper 199. Nameplate (*4) (*1) Parts comprising the spindle Assy (shown in the Figure B). When replacing the spindle Assy, replace all the parts marked with (*1). (*2) Parts comprising the RV gear Assy (shown in the Figure C). When replacing the RV gear Assy, replace all the parts marked with (*2). (*3) For replacement, replace the 2 pieces at the same time. (*4) Parts comprising the rear flange Assy (shown in the Figure D). When replacing the rear flange Assy, replace all the parts marked with (*4). (*5) Parts comprising the piston Assy (shown in the Figure E). When replacing the piston Assy, replace all the parts marked with (*5). Thread size and tightening torque Sign/port Thread size N-m Tightening torque kgf-m 19 M ± ± R3/8 39 ± ± ± ± ± ± M8 29 ± ± W E

12 F-1 F-1 Winch 1.3 Replacing oil seal of the winch motor Once disassembled, oil seals should be replaced with new ones. When disassembling, matchmark every mating face of component to facilitate reassembly. 3. Remove the cylinder block [104]. 1. Remove the plug [33] and drain the gear oil. Then remove the flange [101]. 4. Remove the drum [1]. 2. Send pressurized air into the duct hole for the mechanical brake of the spindle [2] until the piston [112] is protruded slightly out of the spindle [2]. Do not send pressurized air abruptly. Otherwise the piston may pop out of the spindle and create hazard. Reference Pressure of the air: MPa {3 5 kgf/cm 2 } Prevent the retaining ring [26] from being lost because it is necessary for adjusting clearance. Pull the drum vertically upward. If it is pulled up obliquely, it cannot be pulled out because it will interfere with the component inside the winch. While the drum is being pulled out, a pin [17] may drop off onto the surrounding area. When picking up the pin, do not use a sharp tool. 11 W E

13 F-1 F-1 Winch 5. Remove the oil seal [16] Apply a punch on the inner ring surface of the bearing [21] and hit the punch with a hammer. Hit all around the inner ring evenly and remove the bearing from the drum. 6. Remove the oil seal [15] Apply a punch on the inner ring surface of the bearing [20] and hit the punch with a hammer. Hit all around the inner ring evenly and remove the bearing from the drum Apply a punch on the oil seal [16] and hit the punch with a hammer. Hit all around the oil seal evenly and remove the oil seal from the bearing Thrust tools (2 pcs.) with flat and thin ends such as flathead screwdrivers between the oil seal [15] and the drum. Then pry the tools to remove the oil seal [15] from the drum. 12 W E

14 F-1 F-1 Winch 1.4 Performance confirmation test after disassembly and assembly of the motor Installing the motor and arranging piping Arrange piping after the motor is installed. Do not install a wire rope because the test is performed with no load. Arrange piping so that attaching a pressure gauge and measuring the drain amount from the hydraulic motor are possible. Running in the motor Motor revolution Loaded condition Rotational direction 40 min -1 No load Hoist-up Running duration 1 min. or longer Performance test of motor 1 2 Warmup before test: Warm up the machine until the following conditions are obtained. Hydraulic oil temperature: C Temperature at outer surface of speed reducer hub: C Confirmation test: Check the following points and qualify/disqualify the result. (The criteria are described below.) Driving pressure by motor: 1.96 MPa {20 kgf/cm 2 } or below at 40 min -1 with the hoist-up rotational direction Drain amount from the hydraulic motor: 0.1 L/min or below at 40 min -1 Qualified Disqualified Install a wire rope. Disassemble and adjust again. 13 W E

15 F-1 F-1 Winch 2. Support 2.1 General view 14 W E

16 F-1 F-1 Winch Thread size and tightening torque Tightening torque Sign/port Thread size N-m kgf-m 28 M Remarks Apply thread locking agent (Loctite 262T) W E

17 F-1. Winch F Post 11. Spring 21. Support 31. Machine screw 2. Frame 12. Spring 22. Grip 32. Nut 3. Pin 13. Plate 23. Lever 33. Cap 4. Catch 14. Pin 24. Pin 34. Wire rope 5. Machine screw 15. Plate 25. Retaining ring 35. Support 6. Sleeve 16. Snap pin 26. Cover 36. Pin 7. Wire rope 17. Pin 27. Cover 37. Retaining ring 8. Pin Assy 18. Retaining ring 28. Bolt 38. Plain washer 9. Bolt 19. Bolt 29. Guide 10. Spring washer 20. Nut 30. Guide 2.2 Frame stopper adjustment 1. Lower the bucket near to the ground. 2. Raise frame [2] and insert pin [3] to fix the frame [2]. 4. Lower frame [2] and insert pin [3] to fix frame [2]. 5. In this state, check that bolt [19] lightly touches post [1]. 3. Turn bolt [19] from back side of the frame [2] to adjust Dimension A in the fig. below so that bolt [19] lightly touches post [1]. Then lock bolt [19] with nut [20]. - Tuning bolt [19] to the left increases Dimension A. - Tuning bolt [19] to the right decreases Dimension A. 6. If bolt [19] does not lightly touch post [1], repeat steps. 2 to 5 to adjust Dimension A. 7. After adjustment, apply thread lock agent (Loctite 262T) to the thread section of bolt [19], and then lock bolt [19] with nut [20] W E

18 H-1 H-1 Length Detector (for Boom) H-1 Length Detector (for Boom) There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations. 1. Structure and function 1. This detector consists of major parts such as a drum, a wire, and a potentiometer. Connection diagram 2. The unwound wire from the drum is rewound to the drum by the force of spiral spring in the drum. The rotational speed of the drum is reduced by a gear train, and the rotation is transmitted to the potentiometer to make the shaft of the potentiometer turn. The electric resistance of the potentiometer varies in proportion to the shaft rotation, and the length can be detected. Potentiometer Total resistance: 2000 ± 100 Ω Mechanical turning angle: 3600 ± W E

19 H-1 H-1 Length Detector (for Boom) 1. Base plate 6. Packing 11. Nylon clamp 16. Pin terminal 2. Case 7. Seal connector 12. Nylon clamp 17. Collar 3. Drum assy 8. Bracket 13. Gear (A) 18. Cord guide 4. Cover 9. Cable assy 14. Gear (B) 19. Wire assy 5. Packing 10. Potentiometer 15. Pin terminal 2. Disassembly 1. Detach the length detector and the front end of the wire Assy [19] from the positions they are fixed. 5. Remove the potentiometer [10] and gear (B) [14] together with the bracket [8]. When the wire end is detached, be careful so that the wire is not wound in on the drum. The potentiometer is damaged if approx. 700 mm of the wire beyond the yellow tape is wound in on the drum. Operate with care so that the cord is not wound in. 2. While preventing the drum assy [3] from winding up the wire assy [19], wind the portion of the wire assy [19] remaining outside the case [2] around the case, and fix the wire using a packaging tape. Fix the wire firmly to prevent it from slackening during disassembly. 3. Loosen the seal connector [7], and open the cover [4]. 4. Disconnect the connection between the cable assy [9] and potentiometer [10] at terminals, and remove the cover [4] together with the cable assy [9] from the case [2]. 6. Loosen the setscrew and remove the gear (A) [13]. 7. Release the wire assy [19] that is fixed around the case [2], and let the drum assy [3] wind up the wire slowly until the spiral spring does not work any more. Then remove the nuts, and separate the case [2] from the base plate [1]. To facilitate reassembly, put matchmarks on the cover and case under the cord guide. When relieving the spiral spring tension in the drum assy, prevent the wire end from hitting the cord guide. To facilitate reassembly, put matchmarks on the cover and case. 18 W E

20 H-1 H-1 Length Detector (for Boom) 8. Remove the bolt, and separate the drum assy [3] from the base plate [1]. Drum assy 3. Reassembly 1. Put a marker for the zero point on a new wire assy [19] with yellow tape. Then attach an auxiliary string to the looped wire end. Base plate Bolt IW E06 9. If it is necessary to replace the wire assy [19], remove the entire portion of the old wire from the drum assy [3]. 2. Pass the new wire assy [19] through the hole of the drum assy [3]. Then crimp a sleeve-type terminal on the wire end to prevent the wire from coming off. If the spiral spring in the drum assy is broken, replace the whole drum assy. Drum assy Crimp terminal (sleeve type) IW E08 3. Wind the new wire assy [19] and auxiliary string around the drum assy [3] to the zero point indicated by yellow tape, and wind the wire and the auxiliary string further 4 turns around the drum assy. Then fix the wire and the auxiliary string end using a packaging tape to prevent them from loosening. Wind the wire clockwise as viewed from the side of gear mounting. 19 W E

21 H-1 H-1 Length Detector (for Boom) 4. Align the yellow tape (zero point) on the drum assy [3] with the matchmark (indicating the cord guide position of the drum) which has been put on the base plate [1] during disassembly operation. Then fix the drum assy [3] to the base plate [1] using a bolt. 8. Attach the gear (A) [13] and fix it using a setscrew (1 point). Apply thread locking agent to the setscrew. Recommended thread locking agent: Anaerobic high-strength sealant ThreeBond 1324N (made by ThreeBond) Drum assy Base plate Bolt IW E06 5. Apply grease (Moly Speed Grease No. 0) to the bearing portion of the case [2]. 6. Take the end of the wire (auxiliary string) out of the cord guide of the case [2]. Then remove the packaging tape that fixes the wire and the auxiliary string, and place the case [2] over the drum assy [3]. When removing a packaging tape, avoid slackening of the wire. After the packaging tape is removed, keep avoiding slackening of the wire. 7. Align the matchmarks that have been put during disassembly on the base plate [1] and case [2], and fix the case and base plate using nuts. 9. Pull the wire assy [19] and the auxiliary string all the way out of the cord guide on the case [2]. Then make the drum slowly rewind the wire. When the yellow tape (zero point) comes to the edge of the cord guide, stop the drum from further rotating. Wind the wire and the auxiliary string around the case and fix it with a packaging tape. Keep the wire tense until the disassembly is completed. To prevent the drum from winding up the wire after the potentiometer is installed, fix the wire firmly. The potentiometer is damaged if approx. 700 mm of the wire beyond the yellow tape is wound in on the drum. Operate with care so that the wire is not wound in. 20 W E

22 H-1 H-1 Length Detector (for Boom) 10. While applying 5-V DC between the black and white terminals (connector terminals 1 and 3) of the potentiometer [10], adjust the output voltage between the red and black terminals 1 and 2) to the value described below by turning the gear (B) by hand. Output voltage: 0.5 ± 0.05 V If it is not possible to apply 5-V DC, adjust the resistance between the red and black terminals (3 and 2) to the value described below by turning the gear (B) by hand. Resistance: 200 ± 20 Ω 12. Pull the wire assy [19] out of the drum assy [3] slightly. Make sure that the measured resistance between the red and black potentiometer terminals (connector terminals 3 and 2) increases smoothly when the wire is pulled. 13. Connect the terminals of the potentiometer [10] to the ones of the cable assy [9]. 14. Attach the cover [4], aligning the matchmarks that have been put during disassembly. Pay attention to the orientation of the seal connector [7]. 15. Pull the cable assy [9] to remove the slack, and tighten the seal connector [7]. 11. After the adjustment of the potentiometer [10] is completed, attach the potentiometer and the gear (B) [14] together with the bracket [8] on the drum assy [3] while meshing the gear (B) [14] with the gear (A) [13]. After attaching the bracket, measure either the output voltage or the resistance between the red and black terminals of the potentiometer (connector terminals 1 and 2) again to make sure that the value is within the allowable range. If the meshing condition of the gears is too strong, the gears may scratch each other. If it is weak, the gears may be disengaged. When attaching the bracket, check the measuring instrument to keep the output voltage within the allowable range. 16. Release the wire assy and the auxiliary string fixed around the case [2]. 17. Remove the auxiliary string from the wire assy [19]. Attach the length detector to the original position. Install the length detector so that the portion of the yellow tape (zero point) comes to the center of the cord guide. When attaching the length detector, prevent the drum from winding up the wire. The potentiometer is damaged if approx. 700 mm of the wire beyond the yellow tape is wound in on the drum. Operate with care so that the wire is not wound in. 21 W E

23 H-1. Length Detector (for Boom) H Replacing the potentiometer 1. Attach a new potentiometer [10] to the bracket [8], and solder leads to the potentiometer terminals. Solder the potentiometer and leads as quickly as possible to guard the potentiometer from unnecessary heat. Fix the potentiometer terminals and leads using insulating sealant. The following 2 sealant brands are recommended. One-part silicon ThreeBond 1208C or equivalent one-part silicone sealant (ThreeBond) Shin-Etsu Silicone KE45RTV (Shin-Etsu Chemical Co., Ltd.) Orient the terminals of the potentiometer as shown in the figure below. Potentiometer Insulating sealant IW E12 2. Attach the gear (B) [14] to the shaft of the potentiometer [10], and fix it with a setscrew (1 point). Apply thread locking agent to the setscrew. Recommended thread locking agent: Anaerobic high-strength sealant ThreeBond 1324N (made by ThreeBond) 3. Assemble the length detector according to the steps 10. and after in "3. Reassembly" section W E

24 J-1 J-1 Bucket J-1 Bucket There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations. 1. Structure 1.1 Bucket main unit 23 W E

25 J-1 J-1 Bucket 1. Hydraulic motor Assy 13. Pin 25. Frame 37. Fastener 2. Hexagon socket head bolt 14. Plate 26. Frame Assy 38. Spacer 3. Conical spring washer 15. Plate 27. Plate Swing speed reducer 16. Button bolt Guide 5. Cam follower 17. Spring washer 29. Button bolt 41. Slide plate 6. Slide plate 18. Spacer 30. Nut 42. Plate 7. Plate 19. Pin 31. Bolt 43. Spacer 8. Spring washer 20. Grease nipple 32. Post Assy 44. Plate 9. Bolt 21. Cap 33. Pin 45. Plate 10. Nut 22. Split pin 34. Bolt 11. Retaining ring 23. Bolt 35. Spring washer 12. Spacer 24. Plain washer 36. Cylinder Assy 24 W E

26 J-1 J-1 Bucket Note 1. Apply grease (TADANO Genuine grease TNF) to the sliding surfaces (guide rail, slide plates, cam follower) of the bucket elevation frame. 2. Apply molybdenum grease (Never Seez or equivalent) to the areas of the post Assy which are in contact with the frame Assy or swing speed reducer. Apply grease scrupulously to the splines on the shaft. 3. Strike a grease nipple which is one of the cam follower [5] into the end face of the bolt for the cam follower beforehand. 4. Attach the plate [14] at a correct angle. 5. Adjust the bolt so that the bucket does not protrude from the vehicle side when the bucket is stowed, and then apply thread lock agent (Loctite 262T) to the bolt. Thread size and tightening torque Part number Thread size N-m Tightening torque kgf-m 2 M (Provided nut) M M W E

27 J-1 J-1 Bucket 1.2 Swing speed reducer 1. Taper roller 6. Retaining ring 11. Worm wheel 16. Plug 2. Worm 7. Oil seal 12. Gear case 17. Dipstick 3. Taper roller 8. Gear case 13. Ball bearing 4. Shim set 9. Bolt 14. Oil seal 5. Spacer 10. Thrust plate 15. Shaft W E

28 J-1 J-1 Bucket 2. Adjusting slide plates for the bucket elevation frame 2.1 Adjustment before installing elevating frame Before installing the bucket elevating frame onto the bucket swing frame, adjust the slide plate. 1. Refer to the figure in the next page and measure the dimension of the elevating frame (*A) 2. Adjust the shim to make the clearance between the inner faces of the outer slide plates (*B) as described below. See the "Detail of E" in the figure on the next page. *B (clearance between the inner faces of the outer slide plates)... no greater than [*A (dimension of the elevating frame) mm] 2.2 Adjustment during installing the elevating frame Requirement for adjustment Bucket elevating unit stowed (with bucket elevating cylinder fully retracted) Bucket not installed 1. Make sure that the outer slide plates are at the location described in "Adjustment before installing the elevating frame". 2. Install the bucket elevating frame onto the bucket swing frame while holding the elevating to prevent it from leaning. If the bucket elevating frame leans due to the mass of the bucket elevating cylinder, remove the cylinder before installing the elevating frame. Before installing the bucket elevating frame, apply grease (TADANO Genuine TNF) to the slide plates, cam floor bearing, and guide rails for the bearing. 3. Turn the adjuster bolts C and D shown in the figure by hand and tighten them until they turn no longer. (The clearance between the slide plate and the elevating frame becomes 0 mm.) If the turning extent of the adjuster bolts differ, turn both bolt to the smaller extent. 4. Adjust the adjuster bolts A and B in the same manner as the adjuster bolts C and D. 5. Tighten the lock nuts for the adjuster bolts A D to fix the adjuster bolts. Apply Loctite 262T to the adjuster bolts and lock nuts beforehand. 2.3 Operational check of the bucket elevation (after installing the bucket) 1. After installing the bucket, repeat elevation of the bucket, and make sure that the bucket moves smoothly. 2.If the bucket does not elevate smoothly, remove the upper control panel and the bucket, and adjust the adjuster bolts slightly. If the bucket fails to elevate smoothly even after re-adjustment of the adjuster bolts, start all over again from the adjustment of the shim for the outer slide plates. 3. If re-adjustment is performed, apply thread locking agent (Loctite 262T) to the adjuster bolts and fix them. 27 W E

29 J-1. Bucket J W E

30 J-2 J-2 Hydraulic Motor (for Bucket Swing) J-2 Hydraulic Motor (for Bucket Swing) There is a case that the appearance and so on differ from the parts for this machine. Although there is not so much difference in functions and disassembly procedures, make sure of the serial number of this machine and the part sales unit described in the parts catalog before starting disassembling operations. 1. Structure Hydraulic symbol General view 29 W E

31 J-2 J-2 Hydraulic Motor (for Bucket Swing) 1. Screw 10. Housing 19. Screw Flange Dust seal Brake pin 4. Backup ring 13. Drive 22. Nameplate 31. Brake housing 5. Oil seal 14. Seal 23. Rivet 32. Spring 6. O-ring 15. Spacer plate 24. Key 33. End cap plug 7. Thrust bearing race 16. Geroler set O-ring 8. Needle bearing 17. End cap Poppet 9. Output shaft Thread size and tightening torque Sign/port Thread size Tightening torque N-m kgf-m Screw [1] 5/16-2UNF Screw [19] 5/16-2UNF Port A G 1/ Port B G 1/ Pilot port G 1/ Drain port G 1/4 30 W E

32 J-2. Hydraulic Motor (for Bucket Swing) J Geroler set "1. Structure" section. 2.1 Assembling the Geroler set Pay attention to the arrangement of the output shaft, drive and the star of the Geroler set. If the arrangement is incorrect, the motor will turn in the reverse direction. 1. Insert the output shaft in the motor housing with the key groove on the output shaft facing toward you. 2.When the drive is inserted in the output shaft, the valley of a spline will face toward you. 3. Place a spacer plate on the motor housing. 4. Face the side with chamfered splines of star for the Geroler set toward the output shaft. Then engage the star with the splines of the drive with one of its star points 15 counterclockwise away from the center of the key groove. 2.2 How to insert a roller of the Geroler set (if it comes off the Geroler) During assembly, do not hit a roller with a hammer, etc. A Geroler has 7 rollers. The rollers may come off during disassembly/assembly of the Geroler set because they are easy to come off. If a roller has come off, pay special attention to reassemble the Geroler set. Reassemble as follows: 1. Install the star with the ring onto the drive. Make sure that arrangement of the star and ring is as shown in the figure in the "2.1 Assembling the Geroler set" section. 2. Insert rollers around the star. 3. If you cannot insert all the 7 rollers, insert 6 rollers first. Then turn the output shaft gradually holding it with pliers in order to make clearance between the star and ring. 5. Direction of motor rotation (viewed from the motor output shaft) Direction viewed from Pressure port motor output shaft A Clockwise B Counterclockwise For the position of the ports, see the figure in the Before holding the shaft with pliers, cover it with a rag to protect the shaft. 4. When sufficient clearance is available between the star and ring, insert the remaining 1 roller W E

33 Head Office Ko-34,Sinden-cho, Takamatsu, Japan Overseas Service Group Tadano Ryogoku Bldg. 4-12, Kamezawa 2-chome, Sumida-ku, Tokyo, Japan Tel. 81 (3) Tel fax 81 (3) Document Completion:December, History of revision