MH3022, MH3024 and MH3026 Material Handlers Hydraulic System Caterpillar

Introduction

Utilize this procedure to set up the control valve (combined function). The following values are set with this procedure:

• One-way flow or Two-way flow

• Maximum flow

• Maximum pressure

Values for ten work tools can be entered. Procedures are included for utilizing the monitor and for utilizing ET. Utilizing ET is the more precise procedure for setting the flow.

Note: To perform this procedure, the requirements for flow and pressure for the work tool will be needed. Obtain the correct flow and pressure from the manufacturer of the tool.

Required Tools

Illustration 1	g01623868
Tooling (B) 198-4240 Digital Pressure Indicator Gp

Illustration 2	g02422457
Tooling (D) (Flow meter tool layout)

Machine Preparation

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Illustration 3	g02449876
Engine speed dial

1. Set the engine speed dial at "10".

2. Lower the left console.

3. Position the machine on level ground. Check the visibility and adjust the mirrors for the best vision close to the machine.

4. Fully depress the service brake pedal until the service brake pedal locks mechanically.

5. Increase the hydraulic oil temperature to 46° to 60° C (115° to 140° F).

6. Lower the stabilizers and the blade tip.

7. Fully extend the bucket cylinder and place the bucket on the ground.

8. Stop the engine.

9. Release the pressure in the hydraulic system.

   Note: Refer to Testing and Adjusting, "System Pressure - Release".

10. Raise the left console.

11. Release pressure in the hydraulic system. Refer to Testing and Adjusting, "System Pressure - Release".
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    Illustration 4	g03741225
    Stop valves or high-pressure oil delivery to the work tool

12. Install tooling (D) in accordance with the flow meter tool layout to stop valves. Refer to Illustration 2
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    Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the attachments have been lowered, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

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    NOTICE
    Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates.

13. Open stop valves that are mounted on each side of the stick.
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    Illustration 5	g03857086
    Signal pressure taps are located behind the left front access door

14. Attach tooling (B2) 41,368 kPa (6,000 psi) pressure sensor to load sensing signal pressure tap for delivery pressure of the main pumps.
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    Illustration 6	g03722485
    Service connector on the right side of cab behind the seat

15. Connect tooling (E) to the service connector.

16. Start the engine.

17. Set the engine speed dial at "10".

18. Lower the left console.
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    Illustration 7	g02446738
    Power mode control button on the soft panel switch

19. Push down on the power mode control button to activate power mode.

    Note: The indicator light will be illuminated when power mode is activated.

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    Illustration 8	g02447036
    Automatic Engine Speed Control (AESC) as displayed on the programmable function key in the monitor.

20. Disable the automatic engine speed control through the monitor by pressing the programmable button.
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    Illustration 9	g03722432
    Hydraulic modulation switch on left joystick

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    Illustration 10	g06174873
    Hydraulic modulation medium mode (monitor display)

21. Select the hydraulic modulation mode as medium. Press the lower front switch on the left joystick to select the hydraulic modulation mode.

22. The air conditioning should be turned off for the following test.

Test Procedure (Electronic Technician)

1. Start Electronic Technician.

2. Select the Machine ECM.

3. Select “OK”.
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   Illustration 11	g01343612

4. Select “Service” from the main menu.

5. Select “Tool Configuration”.
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   Illustration 12	g01343614

6. Select the desired tool.

7. Select the “Activate” button.

8. Select the “Configure” button.
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   Illustration 13	g01340069

9. Select “One Way/Two Way”.

10. Select the “Change” button.

11. Select “One Way” or “Two Way” from the menu.

    Note: A typical “One Way” tool is a hammer or a compactor. A typical “Two Way” tool is a shear or a grapple.

12. Select “OK”.

13. Select “Yes”.

    Note: For “One Way” tools, only set the “Back Direction” for flow and pressure. Do nothing with the “Front Direction”.

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    Illustration 14	g01343619

14. Select “Tool Program Name” to give the work tool a name.

One-Way Flow

Note: Make sure that “One-way” flow is selected.

Note: Use the flow adjustment procedure before the pressure adjustment procedure.

Flow Adjustment

Note: The maximum pressure for flow "A⇒B" must be set to 35,000 kPa (5,100 psi) before the flow can be set.

1. Select "Tool Program Auxiliary Valve #1 Port A Maximum Load Sense Pressure".

2. Select the “Change” button.

3. Enter a value of 35,000 kPa (5,100 psi).

4. Raise the left armrest. Wait for one second. Lower the left armrest. Alternatively, activate the Implement Lockout and then deactivate the Implement Lockout after a few seconds.

   Note: When the "Tool Program Auxiliary Valve #1 Port A Maximum Load Sense Pressure" is changed, the maximum pressure to the attachment will change.

   Note: The direction of oil flow is controlled by the thumb slider on the right joystick or the optional attachment pedal. Moving the thumb slider in the right direction or the pedal in the forward direction supplies oil to the left line of the tool control "A⇒B". Moving the thumb slider in the left direction or the pedal in the back direction supplies oil to the right line of the tool control "B⇒A".

5. Open valves both stop valves.

6. Select "Tool Program Auxiliary Valve #1 Port A Maximum Flow Configuration".

7. Select the “Change” button.

8. Enter a value from 0 to 250. Start with a value of 125.

   Note: When the "Tool Program Auxiliary Valve #1 Port A Maximum Flow Configuration" is changed, the maximum flow to the attachment will change.

9. Select “OK”.

10. Select “Yes”.

11. Raise the left armrest. Wait for one second. Lower the left armrest. Alternatively, activate the Implement Lockout and then deactivate the Implement Lockout after a few seconds.

12. Set the engine speed dial at "10".

13. Push down on power mode control button to activate the power mode.

    Note: The indicator light will be illuminated when the power mode control is activated.

14. Move the thumb slider to the left position or press the attachment pedal in the back direction.

15. Slowly turn valve on the hydraulic tester (D1) and use the pressure gauge on the hydraulic tester to adjust the pressure to the operating pressure for the tool. Check the flow rate on the hydraulic tester.

16. Repeat Step 7 through Step 15 until the desired flow at the operating pressure is reached.

Pressure Adjustment

Note: Step 1 is only required if the maximum pressure of the work tool is greater than the load sensing signal limiter pressure. Refer to Testing and Adjusting, "Specifications" for the correct load sensing signal limiter pressure.

1. Turn the adjustment screw on the load sensing signal limiter valve in the clockwise direction until the screw contacts the stop. Refer to Testing and Adjusting, "Relief Valve (Signal Limiter) - Test and Adjust".

2. Close valve both stop valves.
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   Illustration 15	g02451617
   Engine speed dial

3. Set the engine speed dial at "5".

4. Push down on power mode control button to activate the power mode.

   Note: The indicator light will be illuminated when the power mode control is activated.

5. Select "Tool Program Auxiliary Valve #1 Port A Maximum Load Sense Pressure".

6. Select the “Change” button.

7. Enter a value from 0 to 35,000. Start with a value of 18,000.

   Note: When the "Tool Program Auxiliary Valve #1 Port A Maximum Load Sense Pressure" is changed, the maximum pressure to the attachment will change.

8. Select “OK”.

9. Select “Yes”.

10. Raise the left armrest. Wait for one second. Lower the left armrest. Alternatively, activate the Implement Lockout and then deactivate the Implement Lockout after a few seconds.

11. Move the thumb slider to the left position or press the attachment pedal in the back direction.

12. Read the pressure on the digital pressure indicator at the load sensing signal pressure tap.

13. Repeat Step 5 through Step 12 until the desired pressure is reached.

    Note: Always make the final pressure adjustment on the pressure rise.

14. Return the load sensing signal limiter valve to the original setting. Refer to Testing and Adjusting, "Relief Valve (Signal Limiter) - Test and Adjust".

Two-Way Flow

Note: Make sure that “Two-way” flow has been selected.

Note: Use the flow adjustment procedure first and then use the pressure adjustment procedure.

Flow Adjustment

Note: The maximum pressure in both directions must be set to 35,000 kPa (5,100 psi) before the flow can be set.

1. Select "Tool Program Auxiliary Valve #1 Port A Maximum Load Sense Pressure".

2. Select the “Change” button.

3. Enter a value of 35000.

4. Select “OK”.

5. Select “Yes”.

6. Raise the left armrest. Wait for one second. Lower the left armrest. Alternatively, activate the Implement Lockout and then deactivate the Implement Lockout after a few seconds.

7. Select "Tool Program Auxiliary Valve #1 Port B Maximum Load Sense Pressure".

8. Select the “Change” button.

9. Enter a value of 35000.

10. Select “OK”.

11. Select “Yes”.

12. Raise the left armrest. Wait for one second. Lower the left armrest. Alternatively, activate the Implement Lockout and then deactivate the Implement Lockout after a few seconds.

    Note: When the "Tool Program Auxiliary Valve #1 Port B Maximum Load Sense Pressure" is changed, the maximum pressure to the attachment will change.

    Note: The direction of oil flow is controlled by the thumb slider on the right joystick or the optional attachment pedal. Moving the thumb slider in the right direction or the pedal in the forward direction supplies oil to the left line of the tool control "A⇒B". Moving the thumb slider in the left direction or the pedal in the back direction supplies oil to the right line of the tool control "B⇒A".

13. Open valves both stop valves.

14. Select "Tool Program Auxiliary Valve #1 Port A Maximum Flow Configuraiton".

15. Select the “Change” button.

16. Enter a value from 0 to 250. Start with a value of 125.

    Note: When the "Tool Program Auxiliary Valve #1 Port A Maximum Flow Configuraiton" is changed, the maximum flow to the attachment will change.

17. Select “OK”.

18. Select “Yes”.

19. Raise the left armrest. Wait for one second. Lower the left armrest. Alternatively, activate the Implement Lockout and then deactivate the Implement Lockout after a few seconds.

20. Set the engine speed dial at "5".

21. Push down on power mode control button to activate the power mode.

    Note: The indicator light will be illuminated when the power mode control is activated.

22. Move thumb slider to the left position or press the attachment pedal in the back direction.

23. Slowly turn valve (D1) on the hydraulic tester and use the pressure gauge on the hydraulic tester to adjust the pressure to the operating pressure for the tool. Check the flow rate on the hydraulic tester.

24. Repeat Step 7 through Step 15 until the desired flow at the operating pressure is reached.

25. Close both stop valves.

26. Reverse lines to the portable hydraulic tester.

27. Open both stop valves.

28. Select "Tool Program Auxiliary Valve #1 Port B Maximum Flow Configuraiton".

29. Select the “Change” button.

30. Enter a value from 0 to 250. Start with a value of 125.

    Note: When the "Tool Program Auxiliary Valve #1 Port B Maximum Flow Configuraiton" is changed, the maximum flow to the attachment will change.

31. Select “OK”.

32. Select “Yes”.

33. Raise the left armrest. Wait for one second. Lower the left armrest. Alternatively, activate the Implement Lockout and then deactivate the Implement Lockout after a few seconds.

34. Move the thumb slider to the right position or press the attachment pedal in the forward direction.

35. Slowly turn the valve on hydraulic tester (D1) and use the pressure gauge on the hydraulic tester to adjust the pressure to the operating pressure for the tool. Check the flow rate on the hydraulic tester.

36. Repeat Step 29 through Step 35 until the desired flow at the operating pressure is reached.

Pressure Adjustment

Note: Step 1 is only required if the maximum pressure of the work tool is greater than the load sensing signal limiter pressure. Refer to Testing and Adjusting, "Specifications" for the correct load sensing signal limiter pressure.

1. Turn the adjustment screw on the load sensing signal limiter valve in the clockwise direction until the screw contacts the stop. Refer to Testing and Adjusting, "Relief Valve (Signal Limiter) - Test and Adjust".

2. Close both stop valves.

3. Select "Tool Program Auxiliary Valve #1 Port A Maximum Load Sense Pressure".

4. Select the “Change” button.

5. Enter a value from 0 to 35,000. Start with a value of 18,000.

   Note: When the "Tool Program Auxiliary Valve #1 Port A Maximum Load Sense Pressure" is changed, the maximum pressure to the attachment will change.

6. Select “OK”.

7. Select “Yes”.

8. Raise the left armrest. Wait for one second. Lower the left armrest. Alternatively, activate the Implement Lockout and then deactivate the Implement Lockout after a few seconds.

9. Set the engine speed dial at "5".

10. Push down on power mode control button to activate the power mode.

    Note: The indicator light will be illuminated when the power mode control is activated.

11. Move the thumb slider to the left position or press the attachment pedal in the back direction.

12. Read the pressure on the digital pressure indicator at the load sensing signal pressure tap.

13. Repeat Step 3 through Step 12 until the desired pressure is reached.

    Note: Always make the final pressure adjustment on the pressure rise.

14. Select "Attachment Pedal Forward Direction Max Pressure Command".

15. Select the “Change” button.

16. Enter a value from 0 to 35,000. Start with a value of 18,000.

    Note: When the "Tool Program Auxiliary Valve #1 Port B Maximum Load Sense Pressure" is changed, the maximum pressure to the attachment will change.

17. Select “OK”.

18. Select “Yes”.

19. Raise the left armrest. Wait for one second. Lower the left armrest. Alternatively, activate the Implement Lockout and then deactivate the Implement Lockout after a few seconds.

20. Press the attachment pedal in the forward direction.

21. Read the pressure on the digital pressure indicator at the load sensing signal pressure tap.

22. Repeat Step 14 through Step 21 until the desired pressure is reached.

    Note: Always make the final pressure adjustment on the pressure rise.

23. Return the load sensing signal limiter valve to the original setting. Refer to Testing and Adjusting, "Relief Valve (Signal Limiter) - Test and Adjust".

Work Tool Setup (Monitor Adjustment)

The following procedure will allow the user to program one of the ten default work tools that are within the machine ECM using the monitor.

This section outlines the procedures for adjusting a tool by utilizing the monitor.

1. Place the engine start switch in the ON position. Do not start the engine.
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   Illustration 16	g03722433

2. The "Home" screen of the monitor is displayed when the key switch for the machine is turned to the ON position. Press the "Menu" key to display the main menu options.
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   Illustration 17	g03724611

3. Use the arrows to select "Service Mode" from the "Main Menu". Press the "OK" key.

4. Input the password "FFF2". Press the "Enter" key.

   Note: The soft switch key pad can be used to enter the desired numbers.

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   Illustration 18	g03741236

5. Select "Tool Programming" from the "Service" menu. Press the "OK" key.
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   Illustration 19	g03741237

6. The ten programmable tools are now displayed. Use the arrows to select the desired tool for programming. Press the "OK" key.

   Note: Press the Save key on this screen to save the parameters to USB memory.

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   Illustration 20	g02554058

7. Use the arrow keys to highlight the parameter. Press the "OK" key to change the default value.

8. Use the arrow keys to change the value or designation of the parameter. Press the "OK" key to enter the change.

   Note: The soft switch key pad can be used to enter a desired number value.

   Note: If the selected solenoid is "Two Way", the parameters for the "Back" direction ("B⇒A") and the "Front" direction ("A⇒B") will be displayed. If the solenoid is "One Way", only the parameters for the "Back" direction ("B⇒A") will be displayed.

9. The following parameters can be modified for each of the tools.

   • Name of the tool

   • Flow direction ("One Way" or "Two Way")

   • Maximum flow for the front direction ("A⇒B")

   • Maximum flow for the back direction ("B⇒A")

   • Maximum pressure for the front direction ("A⇒B")

   • Maximum pressure for the back direction ("B⇒A")

10. Select the desired parameter with the up arrow or the down arrow.

11. Press the "OK" key to enter the change.

12. Change the values with the right arrow or the left arrow.

13. Press the "OK" key to enter the change.

14. Raise the left armrest. Wait for one second. Lower the left armrest. Alternatively, activate the Implement Lockout and then deactivate the Implement Lockout after a few seconds.