M316D, M318D, M320D2, M322D, M322D 2 MH, M322D2 and M324D 2 MH Wheeled Excavators Hydraulic System Caterpillar

Introduction

This test measures the shaft speed of the generator.

Required Tools

Illustration 1	g02478137
Tooling (D)

Machine Preparation

1. Clear all personnel from the machine and from the area around the machine.

2. Start the engine.
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   Illustration 2	g02449876
   Engine speed dial

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

4. Lower the left console.

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

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

7. Increase the hydraulic oil temperature to 46 to 80° C (115 to 176° F).

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

9. Stop the engine.

10. Release the pressure in the hydraulic system.

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

11. Raise the left console.
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    Illustration 3	g02447061
    Service connector located on the right side of cab behind the seat

12. Connect tooling (E1) Cat ET and communication adapter (E2) to the service connector.

Operating States of the Generator

WARNING: High voltage exists at the generator system when the generator is activated.

WARNING

Before making any adjustments to the generator, the engine must be shut off and the main disconnected switch on the magnet controller must be in the OFF position. Close all controller panel doors before the generator is started. Personal injury can occur.

Never handle the leads to the magnet unless the engine is shut off. Personal injury can occur.

Never connect or disconnect the magnet unless the engine is shut off. Personal injury can occur.

Failure to follow this procedure may result in personal injury or death.

There are four time periods in the magnetization cycle of this system and four corresponding voltage levels sent to the magnet.

Illustration 4	g01360673
Operating States of the loaded Generator (Output Voltage with connected magnet) (t1) Boost Voltage time period (t2) Operating Voltage time period (t3) Drop Voltage time period (t4) Magnet OFF Voltage time period (A) Boost voltage 260 +/- 10 VDC (B) Operating voltage 230 +/- 5 VDC (C) Drop voltage -170 +/- 10 VDC

1. The operator first turns the magnet ON. This sends the BOOST VOLTAGE (t1) to the magnet. The Boost Voltage is higher than the Operating Voltage. The higher voltage causes the magnet to quickly achieve full strength. This time period is kept relatively short in order to prevent overheating the magnet. During Boost, the output voltage is 260 +/- 10 VDC.

2. In the next period, the voltage drops to the OPERATING VOLTAGE (t2) level of 230 +/- 5 VDC. This is the regular voltage level for the lifting of material by the magnet.

3. When the operator turns the magnet OFF, the DROP VOLTAGE (t3) is applied in order to release material from the magnet. The Drop Voltage is 170 +/- 10 VDC and reverse in polarity to the Operating Voltage. This reverse voltage initiates a rapid demagnetization of the magnet. The material is actually forced away from the magnet. The Drop Time is relatively short in order to prevent the magnet from magnetizing again from the reversed voltage. The Drop Time may need adjusted due to the type of magnet and type of material being lifted.

4. During the MAGNET OFF VOLTAGE (t4) period, there will still be a low voltage to the magnet due to the inductive behavior of the generator and magnet. When the generator is turning, a minimal voltage (and a weak magnetic field) will be present due to the generator windings that pass through the unamplified magnetic field.

Procedure Steps

Illustration 5	g01111455
Generator Set - Test and Adjust Procedure Steps

Generator Configuration Check

Illustration 6	g01106859
Cat Electronic Technician (Configuration screen) (1) Implement Generator Installation Status (2) Implement Generator Hydraulic Flow Setting

The "Implement Generator Installation Status" (1) should have the "Value" set to "installed" by using the Configuration Screen with ET.

The generator configuration must be identified after installing the generator. Always set the "Implement Generator Hydraulic Flow Setting" (2) to "LOW".

Note: The "HIGH" setting is not used and will not increase magnet performance.

Generator Speed Set

1. Turn the key start switch to the OFF position in order to stop the engine.
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   Illustration 7	g02430785
   Generator switch located on the right instrument panel

   1. Place the generator switch so that the switch is in the OFF position. Push the red lock actuator in order to release the desired position. The generator switch is located on the right console.
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      Illustration 8	g02469076
      Generator (Front View) (3) Generator (4) Stroke limiter screw (5) Valve (Generator) (6) Drive shaft cover

   2. Remove drive shaft cover (6) in order to gain access to the drive shaft of the generator.
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      Illustration 9	g02469077
      Generator with Drive Shaft cover removed (7) Generator Drive Shaft (8) Tachometer (9) Sensor

   3. Attach 1U-6605 Reflective Tape to the flat of the drive shaft (7) of the generator.

2. Start the engine and operate the engine at LOW idle.

   1. Actuate either the boom or stick controls in order to warm the oil to 50 degrees Celsius. Actuate the control to the full extent of the cylinder travel. Hold the control valve in one position for a period with the cylinder stalled. This will help to warm the oil.

   2. Place generator switch in the ON position. Push the red lock actuator in order to release the desired position. The generator switch is located on the right console.

   3. Move the throttle position switch to position 10. The engine is now in HIGH idle.
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      Illustration 10	g02447064
      Joystick (front switch)

   4. Energize the magnet with "LIFT/DROP" switch. Press the front switch on the left joystick in order to energize the generator. This will load the generator while the speed is set.

   5. Use the monitor to verify that the engine speed is at HIGH idle.

      Note: The AESC is disabled when the generator switch on the right console is in the ON position. The generator should now be running.

3. With the magnet ON and the engine at HIGH idle, measure the speed of the generator by using a 9U-7400 Multitach Tool Gp (C).

   The correct operating speed for the loaded generator (magnet on) is 3000 rpm. If the speed is incorrect, adjust the speed of the generator to 3000 ±50 RPM. Generator speed directly affects the output voltage. This procedure should always be followed by adjusting the Operating Voltage.

4. Remove the Hex Head Cap in order to expose the Stroke Limiter screw (4). Adjust the speed of the generator by turning screw (4) of the stroke limiter. Screw (4) of the stroke limiter is located on the valve for the generator.

   • DECREASE generator speed by turning the adjusting screw clockwise.

   • INCREASE generator speed by turning the adjusting screw counterclockwise.

5. Repeat Steps 3 and 4 until the loaded generator speed of 3000 ±50 rpm is achieved.

Operating Voltage Set

WARNING: High voltage exists at the generator system when the generator is activated.

Note: Generator speed should always be set before adjusting the Operating Voltage.

In order to provide a sufficient operating voltage measure the voltage only with a connected and activated magnet. Main disconnect switch and main breaker at the magnet controller must be in the ON position.

Illustration 11	g02469197
15 kW Controller (10) Resistor R1 (11) R1 Variable Resistor Adjustment (12) Boost Timer K7 (13) Drop Timer K12 (14) Terminal Block (AA) Main Breaker F1

Illustration 12	g02469216
Terminal Block (15 kW Version) (15) Terminal "11" (16) Terminal "12"

1. Start the engine.

2. Turn on the generator switch and activate the magnet with the Magnet Lift/ Drop switch.

3. Check the Operating Voltage across terminals "11" (15) and "12" (16) of the terminal block (14). The Operating Voltage should be 230 ±5 VDC.

   If Operating Voltage is 230 ±5 VDC, skip Steps 4 through 6.

4. Turn off the generator and the engine.

5. Set the output voltage to 230 ±5 VDC by adjusting R1 (11).

   • Move the R1 Variable adjustment (11) to the LEFT in order to INCREASE the Operating Voltage of the generator. This will decrease the resistance of R1.

   • Move the R1 Variable adjustment (11) to the RIGHT in order to DECREASE the Operating Voltage of the generator. This will increase the resistance of R1.

   • This adjustment does not affect BOOST or DROP Voltage.

6. Repeat Steps 1 through 5 until Output Voltage is 230 ±5 VDC.

Boost Voltage

The Boost Voltage should be 260 +/- 10 VDC and can be measured during the Boost Time period across terminals "11" (15) and "12" (16) of the terminal block (14). If the Operating Voltage is set correctly, the Boost Voltage should also be correct. Adjustment of the Boost Voltage is not possible.

Boost Time Set

Boost Timer K7 (12) controls the amount of time in which the boost voltage is applied when the magnet is activated. The Boost time should be set to 2 seconds.

Illustration 13	g02469316
Boost Timer K7 (17) Timer dial (18) Multiplier switch "x 1" (19) Seconds/Minutes select switch "S"

• Adjust "K7" Timer dial (17) DOWN only if magnet is hot (90 deg. Celsius) by the end of an 8 hour shift

• Adjust "K7" Timer dial (17) UP to a maximum of 3 seconds only if magnet responds poorly

• "x 1" (18) should be selected (Blocked by epoxy)

• "S" (19) should be selected (Blocked by epoxy)

Note: NEVER adjust BOOST time above 3 seconds. Performance will not be enhanced. Overheating of the magnet can result.

Drop Voltage

The Drop Voltage should be 170 +/- 10 VDC and reverse in polarity to the Operating Voltage. The Drop Voltage can be measured during the Drop Time period across terminals "11" (15) and ."12" (16) of the terminal block (14). If the Operating Voltage is set correctly, the Drop Voltage should also be correct. Adjustment of the Drop Voltage is not possible.

Drop Time Adjustment

Drop Timer K12 (13) and the monitor work in combination to control the magnet drop time. The Drop Timer K12 (13) should be set to 3 seconds. Do not adjust. The switches on the face of K12 (13) should be blocked by epoxy at the factory. All adjustment of "Drop Time" should be adjusted through the monitor (position 1 up to position 11). Drop Time can be adjusted from zero to the upper limit of 3 seconds. This upper limit is set by K12.

Note: NEVER adjust K12 (13). Magnet performance will not be enhanced.

The monitor may require adjustment due to the following:

• Material remains attached to the magnet

• Material is dropped and immediately attracted back to the magnet

1. Set the Drop Time in the monitor to Position "6"

2. Move the magnet into position in order to pick up material.

3. Activate the magnet and attempt to pick up the material.

4. Deactivate the magnet in order to drop the material.

• The Drop Time may be too short if the magnet does not release all of the material. Turn UP the "Drop Time" through the monitor..

• The Drop Time may be too long. The magnet may release the material, but immediately attract the material backup. Turn DOWN the "Drop Time" in the monitor.

• Repeat steps 2 through 4 in order to adjust the Drop Time until the release of material is acceptable.

Adjustment of the DROP Time may be required periodically during daily operation. Adjust the "DROP Time" to compensate for different types, weights, and percent iron content of the material being handled.

The typical "Drop Time" should be between 1 second and 2 seconds. (Position 4 up to Position 8 in the monitor).

Note: Do not repeatedly cycle the same load of material when performing this procedure. The material will become magnetized from the repeated handling.