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Boom Sensors

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42 views9 pages

Boom Sensors

Uploaded by

Fabio Eletrotec
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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BOOM SENSORS

How to verify them

2023

Include:
- Extension Sensor
- Angle Sensor
- Weight Sensor

SAV Dept. – Merlo


05/2023

1
Extension Sensor for TF (Magnetostrictive)

Pin 1 (brown) = +12V (supply)


Pin 2 (green) = signal
Pin 3 (white) = ground
Between Pin1 and Pin3 you have to measure +12V
Between Pin2 and Pin3 you have to measure values below

Example for magnetostrictive sensor P/N 095924 (2600 mm):


0 mt (completely closed) = 0,5V
0,5 mt = 0,5 + 0,77 = 1,27V
1 mt = 1,27 + 0,77 = 2,04V
1,5 mt = 2,04 + 0,77 = 2,81V
…….
2,6 mt (completely extended) = 4,5V

Example for magnetostrictive sensor P/N 095193 (3000 mm):


0 mt (completely closed) = 0,5V
0,5 mt = 0,5 + 0,67 = 1,17V
1 mt = 1,17 + 0,67 = 1,84V
1,5 mt = 1,84 + 0,67 = 2,51V
…….
3,0 mt (completely extended) = 4,5V

The same instruction are valid for all the sensors, using the STD value of 0,5V for the boom
completely closed and 4,5V for boom completely extended. The difference (4,0V) must be
divided for the total length in order to calculate the increase in Volt every meter. For better
test it is recommended to check the values every 0,5mt and to check also that it increase
constantly without any lack.

2
Extension Sensor for PANO and ROTO (Steel Rope)

Pin 1 (brown) = +12V (supply)


Pin 2 (white) = signal
Pin 3 (green) = ground
Between Pin1 and Pin3 you have to measure +12V
Between Pin2 and Pin3 you have to measure values below

Example for sensor with steel rope P/N 117317 (P40.17 - 3595 mm):
0 mt (completely closed) = 0,5V
0,5 mt = 0,5 + 0,56 = 1,06V
1 mt = 1,06 + 0,56 = 1,62V
1,5 mt = 1,62 + 0,56 = 2,18V
…….
3,595 mt (completely extended) = 4,5V

Example for sensor with steel rope P/N 115246 (R50.35 - 5920 mm):
0 mt (completely closed) = 0,5V
0,5 mt = 0,5 + 0,34 = 0,84V
1 mt = 0,84 + 0,34 = 1,18V
1,5 mt = 1,18 + 0,34 = 1,52V
…….
5,92 mt (completely extended) = 4,5V

The same instruction are valid for all the sensors, using the STD value of 0,5V for the boom
completely closed and 4,5V for boom completely extended. The difference (4,0V) must be
divided for the total length in order to calculate the increase in Volt every meter. For better
test it is recommended to check the values every 0,5mt and to check also that it increase
constantly without any lack.

3
Info about length values of steel rope:

Extension between first and second


P/N Model
boom [mm]
P50.18HM 3860
P65.14HM 3760
093643 P120.10HM 4000
ROTO50.21 4385
ROTO50.26 4450
ROTO50.30 5060
111268
ROTO70.24 5060
ROTO50.35 5920
115246
ROTO70.28 5920
P40.12 3095
117316 P40.13 3465
P40.14 3750
P40.17 3595
P50.17 3595
P50.18 3860
117317
P72.10 3750
ROTO40.16 4270
ROTO40.18 3595

4
Angle Sensor (NO SABR)

Pin 1 (brown) = +12V (supply)


Pin 2 (blue) = signal
Pin 3 (green/yellow) = ground

Between Pin1 and Pin3 you have to measure +12V


Between Pin2 and Pin3 you have to measure values below:

Degree [°] V out [V]


-20 1,8
-12 2,1
0 2,5
14 3,0
30 3,5
44 3,9
64 4,3
72 4,4
90 4,5

Angle Sensor (SABR)

Pin 1 (white) = +12V (supply)


Pin 2 (yellow) = CAN H
Pin 3 (green) = CAN L
Pin 4 (brown) = ground

For the SABR check values on MerloTool as it works in CANbus, so it is not possible to measure
values in Volt.

5
Weight Sensor

Pin A (white) = R+
Pin B (green) = S+
Pin C (yellow) = S-
Pin D (brown) = R-

Disconnect the round connector behind the cab and test the value of the resistance as below.
With the boom unloaded (0 Kg), retracted (0 mt) and down (0°) and with horizontal carriage
(0°) it is necessary to measure (with tolerance ±10 Ω):
A+D 352 Ω
B+C 352 Ω
A+B 264 Ω
A+C 264 Ω
B+D 264 Ω
C+D 264 Ω

In case the machine is equipped with 2 weight sensors, repeat the test for each sensor!

6
Then it is necessary to connect it again, open the UGS card and check the values of the tension
that is possible to measure directly on the testing points inside the card, as indicated below:

R+ R- (brown – white) = 5 V
R- S- (brown – yellow) = 2,5 V
R- S+ (brown – green) = 2,5 V
R+ S- (white – yellow) = 2,5 V
R+ S+ (white – green) = 2,5 V
S+ S- (green – yellow) = difference of the signal. This value depends from the weight on the
forks. The acceptable range of this value is between -2 mV and 13 mV.
Repeat this measure with 0 Kg and 1500 Kg on the forks in order to see the variation of mV.
When that value is 25 mV or higher, it indicate a short circuit on the wires or in the weight
sensor itself.

In case the machine is equipped with 2 weight sensors, repeat the test for each sensor!
Disconnect one sensor per time and perform the measurement on the other.

7
8
1500 Kg:

After you can also repeat the test with 1500 Kg on forks and boom at 45°:

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