VM TADANO YORAULIC GRAN SERVICE MANUAL BOOM LENGTH DETECTOR Y-ERVITI J-SRERE O1 TADANO LTD.INTRODUCTION This service manual covers the potentio- meter type boom length detector used in TADANO hydraulic cranes. When starting to repair your length de- tector, first, you must find the Part No. of your detector from the index table given below, and then, select the applicable text in this manual. In servicing the boom length detector, also read other relevant documents in- cluding the WCI Service Manual and Operation and Maintenance Manual. EB A}-UAV=TIETADANON4 FO 992 U- DICER TORI Y 9 4 -FROT— LEE BERGICMERL I LOTT. HEMERICH (0, MENS T- ARs RMT OBMLES Ch Bre FLOWER LID ATEN TSBLERSBRLTE ED. My AMEIICHMOWCL $— CAT=T, RM BEORN 6 OS AMOR eA TREO. Crane model Part No. Model No. of cord cores a BRES 2s 2 FOR I TR-2008 361-302-2006 MA-2aNL~2547 toa TR-250E t 1 t R-300E 361-302-5006 Mg-24N1-3151 1 TR-400E, | 361-301-3006 Maoists aero ea ues ee TR-SO0E ae ' t The contents of this manual are sub- ject to change without notice due to modification. MUR LICL ABER Shs Bad ETO Te CTR KS305-2101 R305—Z101 BOOM LENGTH DETECTOR J-DRERHE @ CONSTRUCTION AND FUNCTION © mie RE The boom length detector mainly con- sists of a recoil spring, cord, reducer, and a potentiometer. The cord is wound on a drum, and is pulled out by the boom as it extends, and is rewound by the recoil spring. The accompanying rotation of the drum is reduced to 1/50 or 1/25 by the reducer, and drives the potenti- ometer shaft. The electric resistance of the potentiometer therefore changes in proportion to the boom length, and the WCI is supplied with the boom length signal in the form of potentiometer resistance. ABEUSM SA. O- KMRL U9 DEBRA TRENCHES, KF KicmATOSI = KES NRONICL 5 TI = AOPMPICIERL TAB UL. BREHSS, CHICMES fo KOMI LAIRR IRIE EST 1/50, BUA L/25 CRBS NAF YY a 3 OMSHTSLRT. LORS NRF IY 21-20 MRSOSHBISGL. CO RAGSWCI AIC GEIST & Hie CF - ARS RL ETS305-2101 305-2101 BOOM LENGTH DETECTOR 1. | 361-302-2006 (wa-24L-2547) | 1. [ 61—302—20006 (MA~24NL— 2647) When the cord is pulled out in the 2 FaRANTmICd| Sih ste EIRENE. LS arrow direction, the reducer, po- af PRERI LY oA FOF VRREOBA tentiometer and the brush of the (COE LIEHDT 5, potentiometer turn and move in the arrow directions. 5 140 Kg+on 2) (BD) (iz2in=1b) erminal connection Gore wire, (Overwind detection & a z Be BRR) i me Reducer me Reduction ratio: 1/25 Mw ik: 1/25 Resistance : 500022500 Electrical turning angle : 355°#2° Potentioneter Mechanical turning angle : 360°, continuous at rotation eee ABI 5000+ 2500 WRIA : a55°+ 2° feiaonIANREA + B60" ARIES ~& 305-2101 305-2101 BOOM LENGTH DETECTOR 2. [361-302-50006 (HA-24NL~3151) | 2. [/s61—s02~s0008 (MA—24NL-8161 ) When the cord {s pulled out in the 2 KeCRATIMICS| SSS ENGEL arrow direction, the reducer, po- BAR ARORF LY 9 A-PDF 9 VREMOBS tentiometer and the brush of the po- (lt RIL EERHT 5 tentiometer turn and move in the arrow directions. POF [ 140 Keon ein E 5 ® g 3) a Sed Core wire (Overwind detection) att Swcaeminm) Reducer mM # i Reduction ratio : 1/50 ae a He: 1750 Resistance : 500042509 Electrical turning angle : 355°#2° Potentiometer Mechanical turning angle : 360°, continuous oe ee rotation AG3iIE + 5000 + 250.0 BRIDES + 855° MAPLES : S60" REETR305~Z101 R305—Z101 BOOM LENGTH DETECTOR 3. 361~301-30006 (MA-24ML-3375) 2. [percaormtone aunenn—ser6) When the cord is pulled out in the arrow direction, the reducer, po- tentiometer and the brush of the potentiometer and the brush of the potentiometer turn and move in the arrow direction. @@G 140 Kem (122in=1b) a DODDS) SS y Cc Bi A] ‘Terminal connection eee 3 Ka ANC SSS LR, RES BA FROERF YY 9 X= BDI ALR BE Kem RIES 3 @ ® Shield wire (Overwind detection) O16 CHR) Core wire (Not used) HELIA + 5000+ 2500 FRR EEA MNO : seo’ HME Se CRA) Reducer a oe Reduction ratio: 1/50 OB He: 1760 Resistance : 500042509 Electrical turning angle : 355°42° Potentiometer Mechanical turning angle : 360°, continuous rotation 355° 2°305-2101 305-2101 BOOM LENGTH DETECTOR DISASSEMBLY DRAWING 0 fhe 1. Case 22. Packing Lovo 22 ty ty 2. Plate 23, Terminal 2 Fu-' 28. SF 3. Cover 24. Terminal Bas 24 eE 4. Bracket 25. Set screw 4 For ob 25. kx aD 5. Drum ass'y 26. Connector BF SLF oer Fy 26, 3ADE 6. Shaft 27. Bolt 6 y47h 21. 7. Slip ring 28. Cable TRV 9TIe 28. 8. Brush 29. Machine screw 8 79% 29. 9. Cord guide 30. Retaining ring 9 3- Rad 80. 10. Gear shaft 31. Bolt 10 #4 7b 31. 11. Ball bearing 32. Nut MKT ey BB 12. Bearing case 33. Self-locking nut 12 “7947-2 83. 13. Reducer 34. Machine screw 18. Ma aa. 14. Gear 35. Machine acrew oe 86. 15, Potentiometer 36. Machine screw 1. BFL Yate 36. 16. Spring 37. Machine screw 16 APE 87 17. Cordlock 38. Machine screw 12 a-Key7 38. 18. Clamp 39. Retaining ring 18 997 39 20. Connector 40. Plate 20. 2498 40. 21, Packing 41. Cord BL Rody 4305-2101 R305~Z101 BOOM LENGTH DETECTOR © DISASSEMBLY AND REASSEMBLY The repair procedures are described under three divisions, REPLACING CORD, REPLACING RECOIL SPRING and REPLACING POTENTIOMETER. Select the procedure ap- plicable to the faults. 1, Replacing cord (Refer to STRUCTURAL DRAWING) 1, After removing connector ® and cord lock @ from the end of the cord, slowly let the cord be wound on the drum until the recoil spring becomes free. Remove the detector ass'y from the boom. 3. Loosen clamp @ and remove cover @. 4. Disconnect cable @ from potentiome— ter @ at the terminals, and remove the cover and the cable together. NOTE yeLift the reducer straight upward, taking care not to tilt it. 5. Loosen set screw ® and remove gear ®, and then, unscrew machine screws 6 and remove reducer NOTE yx Mark an alignment line on case @ and plate @ to record the subcord installation direction. 6. Remove retaining ring@, unscrew nuts@, and take case @ off the drum. 09m, Bane RA 2 9 - KOR. SAM AORIRY THF YY a t—F ORB’ OB DICAMLTHMLET. MMOKRUCUTRARA BERD I A, RAO T CRED. 1, - KOR ait) 1 3 FSD IA FB, 2- KO IDENL, 2 ~ KERB ADI LE BETOD CDE RIA IBRMBES, 2 HBT eV TIT ADOMOMT. 8 IL IBERYTHN-OENT. APO DWBLE TTY 9 4 FOO ETM CH Ly RSET LEBER ONT. Terminal er 5. bx ATSEMOTETOENT, MICEABEAL, MRD em) HT. ee A RMRBIAROLSME CLEATS, 6 LIVLIB, Hy hOBALE-2DEK PME Be ae KFA KORMAGEMSRORV—-7ET =2Q, Fe-+@eoueaw<. ”305-2101 R305~Z101 BOOM LENGTH DETECTOR Subeord gubcord pisaneent line 7. Unscrew self-locking nut@, and se- 7 Ut> KOBNL, KSAT SRL TI@LFL-b parate drum assembly ® from plate @. Ornms a. 8. Disconnect the cords from brushes® — 8 KF AT oe FIOKMIAVSNTHSTIL® mounted on drum assembly ® by un 23 = FORAY FHT) ENT. soldering. l-core cord type 1B947, cord type 7 9. Remove the entire old cord from the II-B RRSAT RVI IDOETHT, drum assembly.305-2101 305-2101 BOOM LENGTH DETECTOR The values in the descriptions of AFORE CHT < SRE, REMC work procedure given in the subse RHHOLT, RUM TROMMERSOS A, pages differ with the models of the HRERRUTC ESL. length detector. The concrete values are given in the table below. No. of Length length |position |@tt® turns] outside aus ition ||‘Biturne | detector ae Oy mM) amen | mares a Os Em Boom length de-|Ne¥ cord |O-mark tector part No. FH 5H UNE ies 361-302-20006 (maczant-2547) | 25-5 4.95 45 47 50002250 | 50060 361-302-5006 " (wa-zant—3151) | 318 5.35 45 5.1 5000#250 | 50060 a ae 34 7.75 4.5 1S s000#250 | soat60 (MA-24ML-3375) FHBTS. £4. MICRO BI ET“ FCP NBIC o> 10. Prepare a new cord having a length of 10, #LN3— [4] m for the detector model on hand. filibie FOR Install the O-marker to the cord at pemottis, [5] mas shown firmly by adhesive tape. Drum end o-marker Sat et 5 a -305-2101 305-2101 BOOM LENGTH DETECTOR CAUTION H. HI-KERDAT yeYTIOORIML, MOH LOBEMTT 5 LOIN THOT. 2-CORE CORD TYPE ONLY $e OORE WIRE: CONNECT TO INNER BRUSH Labruital YrSHIELD WIRE : CONNECT TO OUTER Re A= K2GI4 TOH WI KR BIO TIL CHEE NoTE SLR BIOS oc tR weCompletely insulate the soldered joint. Be 11, Thread the new cord through the Shy HUMBERT SCL, hole in drum assembly ®, and solder it to brushes ® by reversing the disconnection procedure. | 1-core cord type ao eiee ty Wind vinyl tape caaaevewe Vinyl cube E“ir08rs.) ry Mass“grease. | SL Exoeem | Vinyl tube etapa core wire Staple Gnside) Bk am Pel) Ineulate vith HI-BOND tape Niet 7 ee eu mastin ) Shield wire (cutsige) oF BE a) Wind vinyl tape eonar vend305-2101 305-2101 BOOM LENGTH DETECTOR NOTE ind the cord counterclockwis« viewed from the brush si 12. Wind the new cord around the drum assembly without slack. From the O-marker at [B] m, further wind the cord [B] turns, and secure the cord to the drum with a gummy adhe- sive tape or the like. 12 HLOI= KICOAAMHOES KILT oUF DICBRHY 50 [BlmO [ORF J KIA IC Hib, TOME ORICDIE RIBS HTS — KOO SLES HAF —-FECHET BS. ze wea KOBSHURA, 75 UMDSRTR MATS. NOTE . YrSolder only to the inner ring, when the cord is of 1-core type. 13, When replacing slip ring®, solder the cord core wire to the inner ring, and the shield wire to the outer ring. Then, with adhesive applied to the mating surfaces and to the screw holes, install it to plate ® by properly tightening screws @. Apply contact grease here ——_ Bayete Shield wire (outer ring), AWE ONL) 14, With the flat on shaft ® aligned, install drum ass'y © on plate®, and secure it with self-locking nut @. Tightening torque : 220 — 250 kg.cm (491 = 217 in-1by 10 18. AV oS I TORRAT SBI, Abaca — F DERE AMMICY VRE SHUTS. UTR DUH OE AA CHER CORY F ) ett Ly EABSRMICHOTTL— KOICMD AZ. ze WA KI TEARMOBENY Fhe Fe3. Core wire (nner ring) seme) Mh. Ye 7 OOURMERDETKILT eV FI® BTL hOKMOKU, UF > KOTEET SZ. WHY hoy + 220~250%8+00305-2101 R305~Z101 BOOM LENGTH DETECTOR 15. With packing @ coated with adhesive, 15, place case @ over drum ass'y ®. In this case, extend the subcord to the outside through the recess in the case. 16. Secure case @ and plate @ with nuts @and install retaining ring @. 17, Pull out the new cord through the 17. guide window, to the end, and then, slowly let it be wound on the drum. When the O-marker has come to the center of the cord guide, secure the cord in that position with adhe sive tape as shown. o-marker Tome?) hy RY QIEER (RD K) RURAL. 47-20% FIAT 2 eUTIOKDERS. LOB, HF 2— FRY 20M 5 HCH Te F-ADEFL-bO*Fy MOTEL, 9 LOY FORO Be SMO KRU ORLY REET WoC DEKFLICBAME LSS asthe Fome— 7) aa- Fat FONICR EB. ZO {eT - KeROMICEET 3. 18, Install reducer ® to bearing case ® . 18 Apply screw locking compound to screws B. Tightening torque : 14 kg.cm (12.2 in-1b) 19. Secure gear @to the shaft of re- 19. ducer @ by tightening set screw @ against the flat area on the shaft. Apply screw locking compound to the set screw. Tightening torque : 14 kg.cm (12.2 in-1b) Adhesive tape ware? BARDEXT IY 7 —2QICM ONS. ERB RADE DAARHTS. BEAD kere FP ORRRAOOMOURATI * ASIC FBo LF ALICIA Oo THERE. WH AD 2 A Keren When the potentiometer itself is faulty, replace it, referring to the procedures * described under REPLACING POTENTI- OMETER. 20. With gear @ mounted on the shaft 20, of potentiometer @, set spring ® in the holes in bracket @ and the gear. Then, to eliminate the back- lash by the spring tension, bring the gear in engagement with the gear on the reducer after turning through approximately 180° in the boom ex- tending direction (refer to struc— n REY aA FIERBD BBO, BOA a4 FORM’ EBRL, COMATRAT RF YY a t-2OOMIEE DEAN, ATI BETIT > hOREX YORI y hPS. TUT RyPF oY aM DAT IY INGSABBI, ¥ PET AKEHOMRAM (MiBBSM ) #9 180° BL ft CRD LAYS. FUT Ry DF 9 Ya BRIM EY OMAR DAC STOR CL RMRTS, HPTOUMBI, FIT » KOO EME TB.305-2101 21. 22. 305-2101 BOOM LENGTH DETECTOR ture drawing). Then, check for suf- ficient elimination of backlash. If backlash is not completely eliminat- ed, readjust the position of bracket o. Spring fastening hole for the systen in which potentioneter turns COW as boom extends. Feed, Fo sa FAMBMOAT IS TRAR Connect the terminals of cable ® 21 and potentiometer @. (Refer to connection diagram in the structure drawing.) Measure the resistance of the poten- 22, tiometer. First check the resistance across terminals © and O of connector @for [F}Q , and then, turn the po~ tentiometer shaft until the resis— tance across ® and ® becomes Lock gear ® with set screw @ in this position with screw locking com- pound applied to the screw. Tightening torque : 14 kg.cm (12.2 in-1b) ete ‘Terminal cable Spring fastening hole for the ‘system in which potentioneter turns GW as boom extends, Fa, 87 og EES BRUM DAT Io RR 2 -FHOMOBEE RF LY a 4-2 OOME ER e52, CERO eR ) Vest F ORME STD. KT IAD QowFO-OMoRRS OTS SCL ERD Ly KICK FY Ya x - 2 OF SEL TO-OM OE MOG) Oiete 2 UMC Tak x AL HTE YD: Bo A ADICRAD Oy DR EBHTS, REE NOV? = LA geen Connector g Ms Sablew Sao 2305-2101 BOOM LENGTH 23. Pull the cord slightly out of the drum, and see if the resistance in- creases smoothly. 28. 24, Install cover ® with clamp ® brought 24 to a position opposite from the po- tentiometer position. At this time, apply water resistant sealant and adhesive respectively on the case side and the cover side of packing ®. 25. Pull cable @ to eliminate slack, 26. and tighten clamp @ . 26. Install cord lock @to the end of 26. cord@, and install the wires; and connector @ to the cord end. Fully insulate the soldered part. 305-2101 DETECTOR BO KEKS LS DUAR, MIMI A LX We 6 CL SMT 5 2 ABOWRERF LY a t—2ORMMICL ESICLTAN-ORMONU S. COB, No Y Qty — Amicpieko — eRe, 2 <— MUCHA CORD K) BiRTIL THK Ce FA FVBRINORY, OLARL OTHE IIL, BrDS, 3 = FOCI - Foy >OeMmO FH, I-K ORMBIC — FR, DAP SBRMOHttS. nv FIRB, RAIL TIL TL o-marker Lh one s0(2.0 in.) 20.28 sn. Thee} 100.4 40.) a key NOTE srFor the relative positions of the connector terminals in the connector case, refer to the structure drawing. ja SE... fit S0i2.8 tne) Lead wire Lead 27. Check continuity between the sub- cord connector and cord connector, and for absence of shorting. Subeo! sess Connector n78 B Tee ¢ oto EROB BUTT 2, Wind HI-BOND tape to protect against water, and thon wind an ineulating tape. FERC. Sa sn) 30K WARIS T-2LAAD OMFOMEMM(S, MERESRLT EO. PI2-KOIRYHED—~KOIAT SMFMOM HIAN ROMROAR RET 5. Core Connector Shoe305-2101 305-2101 BOOM LENGTH DETECTOR 2. Replacing recoil spring When the recoil spring is broken, re~ place the entire drum assembly ®, For this, disassemble and reassemble the boom length detector in the same way as in "REPLACING CORD" 3. Replacing potentiometer NOTE yeWhen the cord or the recoil spring is also defective, remove the detector assembly from the boom before start- ing to repiar it When only the poten- tiometer is defective, the detector assembly need not be removed. 1. Loosen clamp@®, and remove bolts @ and cover @ . 2. Disconnect the potentiometer leads from cable @, and remove the poten- tiometer together with the bracket. 3. Remove gear @ and spring, and remove the potentiometer from the bracket. 4, Install a new potentiometer, and con- mect the leads to cable ®. (Refer to the connection diagram in the structure drawing.) 5. With the boom fully retracted, ad- just the cord with the cord lock so that the O-marker comes to the center of the cord guide. “ ALORA LY at 7 ORO, 2. SE RORIA RAKABMMALEBEI, FIAT yey TIOoM WCRI S, AM MACE, HRD *3— KO BBR RU THES. 8. RFLS aX-FORM ze WANK SANRERCR RMD SBS WET y eV IV ET—AHSMO ALTER FECL, RFVY a X—-FORCRMBSS BS RUEMOATERESD ELA, L 29 VIBEOS ORI HUD HNO. YA BEDI — RET PURO FLY ak BRTIT y KERIENT Bracket Foret 8 FFD. ATI IOERL, RF VY a x FET Dry hDEALET. Ke TF UBICIRRET 5. Ha HEEL BI) 5. 7h eRHLERIETA — K LO [ORY —9 J BS KAT KORMICC BBR I= Ky DIC ars,305-2101. 305-2101. BOOM LENGTH DETECTOR Cord lock SU kos> 6. Procede with the reassembly by following the procedure 20 onward in REASSEMBLY under "REPLACING CORD", given above. © ADJUSTMENT 1. With the boom fully retracted, adjust the cord with the cord lock so that the O-marker comes to the center of the cord guide. parery 2. Adjust the length display of WCT. (Refer to the service manual for the WCT.) ve onnarker Fore) 6. EE, BBD “a - FORM’ OFA 20. LUN LHI OBB CHER SITES. 1 F- ASSL IRS — FED [ORS 7 J BO — FAT ROAICS BB 2 Ke PIT wre. 2 WCLORSRRMM ETD. (WCLOY-ERT=T EBM)Bgl TADANO PRINTED IN JAPAN ©2006 TADANO LTD.