Supplemental Custom Product Support Literature for a Factory Installed 20 kW Right Front Corner Mounted Generator Set ( 291-9575 Hydraulic Generator Arrangement ) and the Operation Instructions{4450, 7000} Caterpillar

Excavator:

330D (S/N: MWP1-UP)

Introduction

Illustration 1	g01051135

This special instruction is a supplement to the Service Manual and Parts Manual for your machine. Also, refer to the supplemental Parts Manual, SEBC0660. This special instruction outlines the operating procedures for excavators that are equipped with a 20 kW generator that is mounted on the right front corner. The separate sections will describe the differences between the excavator that is equipped with a magnet and the standard machine. Refer to Systems Operation, RENR3825 for the operation of the solid-state magnet controller. Refer to Systems Operation, RENR3825 for the operation of the hydraulic manifold and the hydraulic manifold components. Refer to Electrical Schematic, RENR3125 for the details of the solid-state magnet controller. Some excavators are configured with a provision for a grapple. This publication does not include information for a grapple. The special instruction will describe the information for the following topics: Operation, Maintenance, Systems Operation and Testing and Adjusting.

Refer to the appropriate Parts Manual, Operation and Maintenance Manual, and Service Manual for your standard machine.

Parts Information

291-9575 GENERATOR AR

Table 1

HYDRAULIC SYSTEM
291-9575 GENERATOR AR
PIN (S/N: MWP1-UP)
NOTE			PART NAME							TABLE REFERENCE
	PART NUMBER	QTY	1	2	3	4	5	6	(Product Level)
Y	239-9489	1	ADAPTER GP							2
Y	291-9592	1	FRAME GP - UPPER							3
Y	273-7597	1	GENERATOR AR							4
Y	291-9591	1	INSTALLATION AR							5
	291-9593	1	FRAME AS - UNDERCARRIAGE

·

·

239-9489 ADAPTER GP

Table 2

HYDRAULIC SYSTEM
239-9489 ADAPTER GP
PIN (S/N: MWP1-UP)
PART OF 291-9575 GENERATOR AR
NOTE			PART NAME							TABLE REFERENCE
	PART NUMBER	QTY	1	2	3	4	5	6	(Product Level)
	7Y-3550	1	PIN
	8T-4132	2	NUT (M16X2 - THD)
	188-2315	1	BOLT (M16X2X195 - MM)
Y	234-1260	1	LINK GP							6

·

·

291-9592 FRAME GP - UPPER

Table 3

HYDRAULIC SYSTEM
291-9592 FRAME GP - UPPER
PIN (S/N: MWP1-UP)
PART OF 291-9575 GENERATOR AR
NOTE					PART NAME							TABLE REFERENCE
	REFERENCE NUMBER	ILLUSTRATION NUMBER	PART NUMBER	QTY	1	2	3	4	5	6	(Product Level)
A	1	2	093-0074	2	SHIM (1 - MM THK)
	2	2	093-0090	4	SHIM (1 - MM THK)
	3	2	093-0364	2	SPACER (103X140X12 - MM THK)
	4	2	096-6467	2	WASHER (22X60X8 - MM THK)
	5	2	133-2427	2	SHIM (0.5 - MM THK)
	6	2	201-2771	1	WASHER (26X90X8 - MM THK)
A	7	2	212-2841	2	SHIM (2 - MM THK)
	8	2	251-2542	1	PIN AS
	9	2	291-9574	1	FRAME AS - UPPER
	10	2	093-0106	1	SHIM (2 - MM THK)
	11	2	117-5435	2	PIN AS
A	12	2	142-4901	16	SCREW (M10X1.5X20 - MM)
	13	2	147-3957	1	SHIM (0.5 - MM THK)
	14	2	166-1488	4	SHIM (2 - MM THK)
	15	2	7X-2572	1	BOLT (M24X3X35 - MM)
A	16	2	8T-4121	4	WASHER (11X21X2.5 - MM THK)
	17	2	8T-4123	1	WASHER (22X35X3.5 - MM THK)
A	18	2	8T-4133	16	NUT (M10X1.5 - THD)
	19	2	8T-4167	1	WASHER - HARD (26X44X4 - MM THK)
	20	2	8T-4780	2	NUT (M20X2.5X30 - MM)
A - USE AS REQUIRED M - METRIC PART

Illustration 2	g01801253

273-7597 GENERATOR AR - HYDRAULIC

Table 4

HYDRAULIC SYSTEM
273-7597 GENERATOR AR - HYDRAULIC
PIN (S/N: MWP1-UP)
PART OF 291-9575 GENERATOR AR
NOTE			PART NAME							TABLE REFERENCE
	PART NUMBER	QTY	1	2	3	4	5	6	(Product Level)
Y	273-6394	1	GENERATOR GP - HYDRAULIC							11
Y	273-6395	1	ELECTRONICS GP - MONITOR							7
Y	273-6397	1	FILTER & LINES GP - HYDRAULIC							8
Y	273-6400	1	WIRING GP - HYDRAULIC GENERATOR							9
Y	279-6064	1	LINES GP - HYDRAULIC GENERATOR							10
	135-1669	2	CONNECTOR
	135-1670	2	CONNECTOR

·

·

291-9591 INSTALLATION AR

Table 5

HYDRAULIC SYSTEM
291-9591 INSTALLATION AR
PIN (S/N: MWP1-UP)
PART OF 291-9575 GENERATOR AR
NOTE			PART NAME							TABLE REFERENCE
	PART NUMBER	QTY	1	2	3	4	5	6	(Product Level)
Y	179-3625	1	PUMP GP - GEAR							16
Y	191-5537	1	DRIVE GP - AUXILIARY PUMP							17
Y	245-1741	1	WIRING GP - CONVERTER							23
Y	259-7598	1	CONTROL & MTG GP - JOYSTICK							29
Y	261-4485	1	LIGHTING GP - CHASSIS							20
Y	272-3274	1	PANEL & MTG GP - CIRCUIT BREAKER							24
Y	272-5821	1	COVER GP - ACCESS							26
Y	291-9559	1	WIRING GP - HYDRAULIC GENERATOR							19
Y	291-9581	1	FENDER & COVER GP							27
Y	291-9588	1	HANDRAIL GP							22
Y	291-9599	1	LINES GP - AUXILIARY HYDRAULIC							28
Y	291-9613	1	ENCLOSURE GP - GENERATOR							18
	148-7194	1	FILM - IDENTIFICATION
	276-5711	1	FILM - FUSE PANEL
	279-0775	1	FLIM - INSTRUCTION
	8T-4185	1	BOLT (M10X1.5X50 - MM)

·

·

234-1260 LINK GP

Table 6

HYDRAULIC SYSTEM
234-1260 LINK GP
PIN (S/N: MWP1-UP)
PART OF 239-9489 ADAPTER GP
NOTE					PART NAME							TABLE REFERENCE
	REFERENCE NUMBER	ILLUSTRATION NUMBER	PART NUMBER	QTY	1	2	3	4	5	6	(Product Level)
A	1	3	188-4040	2	SPACER (95X175X1.6 - MM THK)
	2	3	215-6729	1	WASHER (54X98X8 - MM THK)
	3	3	215-7054	1	PIN
	4	3	215-7516	1	NUT (M52X3 - THD)
A	5	3	225-3674	2	SPACER (95X175X19.1 - MM THK)
	6	3	233-9905	1	SLEEVE
	7	3	234-1259	1	LINK AS
	8	3	095-0865	1	PIN - COTTER
A	9	3	225-3673	2	SPACER (95X175X14.3 - MM THK)
A - USE AS REQUIRED M - METRIC PART

Illustration 3	g01521368

273-6395 ELECTRONICS GP - MONITOR

Table 7

HYDRAULIC SYSTEM
273-6395 ELECTRONICS GP - MONITOR
PIN (S/N: MWP1-UP)
PART OF 273-7597 GENERATOR AR - HYDRAULIC
NOTE					PART NAME							TABLE REFERENCE
	REFERENCE NUMBER	ILLUSTRATION NUMBER	PART NUMBER	QTY	1	2	3	4	5	6	(Product Level)
	1	4	166-4703	1	MONITOR
	2	4	260-1935	1	HARNESS AS - CONTROL
	3	4	261-0984	1	BRACKET AS
	4	4	8C-9660	2	WASHER (4.6X7.9X0.8 - MM THK)
	5	4	8T-9405	2	BOLT - SOCKET HEAD (M4X0.7X16 - MM)
	6	4	096-0061	10	STRAP - CABLE
M - METRIC PART

Illustration 4	g01527958

273-6397 FILTER & LINES GP - HYDRAULIC

Table 8

HYDRAULIC SYSTEM
273-6397 FILTER & LINES GP - HYDRAULIC
PIN (S/N: MWP1-UP)
PART OF 273-7597 GENERATOR AR - HYDRAULIC
NOTE					PART NAME							TABLE REFERENCE
	REFERENCE NUMBER	ILLUSTRATION NUMBER	PART NUMBER	QTY	1	2	3	4	5	6	(Product Level)
	1	5	6N-4445	1	BRACKET
	2	5	148-8328	2	CONNECTOR AS
	3	5	148-8370	2	ELBOW AS
	4	5	274-5225	1	HOSE AS
	5	5	274-6072	1	HOSE AS
	6	5	289-8194	1	FILTER GP - OIL
	7	5	296-8146	1	TUBE AS
	8	5	148-8370	1	ELBOW AS
	9	5	190-4885	2	SPACER (11X22X50 - MM THK)
	10	5	4B-0418	2	CLIP
	11	5	6D-4246	1	CLIP
	12	5	6V-8398	1	SEAL-O-RING
	13	5	8B-0544	3	SPACER (1 - IN THK)
	14	5	8D-9671	3	CLIP
	15	5	8T-4121	11	WASHER - HARD (11X21X2.5 - MM THK)
	16	5	8T-4133	1	NUT (M10X1.5 - THD)
	17	5	8T-4136	1	BOLT (M10X1.5X25 - MM)
	18	5	8T-4137	3	BOLT (M10X1.5X20 - MM)
	19	5	8T-4185	3	BOLT (M10X1.5X50 - MM)
	20	5	8T-4195	1	BOLT (M10X1.5X30 - MM)
	21	5	8T-5005	2	BOLT (M10X1.5X70 - MM)
M - METRIC PART

Illustration 5	g01528300

273-6400 WIRING GP - HYDRAULIC GENERATOR

Table 9

HYDRAULIC SYSTEM
273-6400 WIRING GP - HYDRAULIC GENERATOR
PIN (S/N: MWP1-UP)
PART OF 273-7597 GENERATOR AR - HYDRAULIC
NOTE					PART NAME							TABLE REFERENCE
	REFERENCE NUMBER	ILLUSTRATION NUMBER	PART NUMBER	QTY	1	2	3	4	5	6	(Product Level)
	1	6	194-0463	1	CABLE
	2	6	7K-1181	10	STRAP - CABLE
M - METRIC PART

Illustration 6	g01554794

279-6064 LINES GP - HYDRAULIC GENERATOR

Table 10

HYDRAULIC SYSTEM
279-6064 LINES GP - HYDRAULIC GENERATOR
PIN (S/N: MWP1-UP)
PART OF 273-7597 GENERATOR AR - HYDRAULIC
NOTE					PART NAME							TABLE REFERENCE
	REFERENCE NUMBER	ILLUSTRATION NUMBER	PART NUMBER	QTY	1	2	3	4	5	6	(Product Level)
	1	7	8T-4834	1	TEE - SWIVEL ORFICE
	2	7	131-9203	1	SWITCH AS - PRESSURE
	3	7	279-6066	1	HOSE AS
	4	7	279-6069	1	HOSE AS
	5	7	3J-1907	1	SEAL-O-RING
	6	7	5K-9090	2	SEAL-O-RING
M - METRIC PART

Illustration 7	g01528697

273-6394 GENERATOR GP - HYDRAULIC

Table 11

HYDRAULIC SYSTEM
273-6394 GENERATOR GP - HYDRAULIC
PIN (S/N: MWP1-UP)
PART OF 273-7597 GENERATOR AR - HYDRAULIC
NOTE			PART NAME							TABLE REFERENCE
	PART NUMBER	QTY	1	2	3	4	5	6	(Product Level)
	8T-4121	16	WASHER - HARD (11X21X2.5 - MM THK)
	8T-4196	16	BOLT (M10X1.5X35 - MM)
	8T-7338	4	BOLT (M16X2X45 - MM)
	9X-8257	4	WASHER (17.5X30X3.5 - MM THK)
	164-0574	4	MOUNT AS
Y	308-0147	1	GENERATOR GP - HYDRAULIC							12

·

·

308-0147 GENERATOR GP - HYDRAULIC

Table 12

HYDRAULIC SYSTEM
308-0147 GENERATOR GP - HYDRAULIC
PIN (S/N: MWP1-UP)
PART OF 273-6394 MOUNTING GP - GENERATOR
NOTE					PART NAME							TABLE REFERENCE
	REFERENCE NUMBER	ILLUSTRATION NUMBER	PART NUMBER	QTY	1	2	3	4	5	6	(Product Level)
	1	9	6I-6721	2	ELBOW
	2	8	7K-1181	6	STRAP - CABLE
	3	9	7X-5308	4	CAP - DUST
	4	8	8J-1256	1	CLIP
	5	9	9U-5872	1	INSERT - COUPLING
	6	8, 9	062-5388	2	LOCKNUT (1-11-1/2 - THD)
	7	9	068-3708	1	LOCKNUT (1-11-1/4 - THD)
	8	9	104-3648	1	BUSHING
	9	8	104-3650	1	BUSHING
	10	9	136-1122	8	BUSHING
	11	9	148-8370	1	ELBOW AS
	12	9	161-1266	1	MOUNTING GP - MOTOR
	13	9	164-5567	2	COUPLER AS - QUICK DISCONNECT
	14	9	164-5586	1	TEE AS
	15	8	170-8599	2	FILM - WARNING
	16	8	171-4667	1	COVER
	17		178-3339	4	SCREW (8-32X0.5 - IN)
	18	8	178-7240	1	FILM - INSTRUCTION
	19	9	180-7100	1	COUPLING
	20	9	180-7101	1	COUPLING
	21	9	180-7109	1	RING - RETAINING
	22	8	185-0609	1	PLATE - IDENTIFICATION
	23	8	189-2988	1	GENERATOR GP - HYDRAULIC
	24	9	190-9372	1	CONNECTOR
	25	8	201-9908	1	FILM - INSTRUCTION
Y	26	8	251-8483	1	MOTOR GP - HYDRAULIC GENERATOR							14
	27	8	253-6148	1	HARNESS AS - POWER
	28	8	273-7205	1	HARNESS AS
Y	29	8	289-3972	1	PANEL GP - CONTROL							15
	30	8	308-0150	1	SUPPORT AS
	31	9	317-7370	1	CONNECTOR
	32	8	317-9128	1	HARNESS AS
	33	9	323-2194	1	FUSE AS
	34	9	110-6349	2	FITTING AS
Y	35	9	160-5885	1	VALVE GP - FLOW CONTROL & RELIEF							13
	36	8	202-2762	2	CLIP
	37	9	1P-3703	2	SEAL - RECTANGULAR
	38		4B-2043	4	NUT (8-32 - THD)
	39		4B-4863	8	WASHER (4X11X1.2 - MM THK)
	40	8	4D-7388	2	CLIP
	41	8	4S-8264	4	RIVET - POP
	42	8	5C-2890	7	NUT (M6X1 - THD)
	43	8	5C-9553	7	BOLT (M6X1X16 - MM)
	44	9	5K-9090	2	SEAL-O-RING
	45	8	5P-2566	4	BOLT (1/2-13X1.5 - IN)
	46	8	6V-7687	4	LOCKNUT (M12X1.75 - THD)
	47	8	6V-7744	3	LOCKNUT (M10X1.5 - THD)
	48	9	6V-7970	1	SEAL-O-RING
	49	9	6V-8398	1	SEAL-O-RING
	50	8	7X-0346	2	BOLT (5/8-11X2 - IN)
	51	9	7X-7960	8	BOLT (M12X1.75X220 - MM)
	52	8	8K-1433	1	GROMMET
	53	8	8T-4121	13	WASHER - HARD (11X21X2.5 - MM THK)
	54	8	8T-4122	2	WASHER - HARD (17X32X3.5 - MM THK)
	55	8	8T-4133	2	NUT (M10X1.5 - THD)
	56	8	8T-4137	2	BOLT (M10X1.5X20 - MM)
	57	8	8T-4195	5	BOLT (M10X1.5X30 - MM)
	58	8	8T-4196	1	BOLT (M10X1.5X35 - MM)
	59	8	8T-4205	10	WASHER - HARD (7.2X14.5X2 - MM THK)
	60	8	8T-4223	12	WASHER - HARD (13.5X25.5X3 - MM THK)
	61	8	8T-4910	4	BOLT (M12X1.75X60 - MM)
	62	9	8T-7491	1	CONNECTOR
M - METRIC PART

Illustration 8	g01529914

Illustration 9	g01531636

160-5885 VALVE GP - FLOW CONTROL & RELIEF

Table 13

HYDRAULIC SYSTEM
160-5885 VALVE GP - FLOW CONTROL & RELIEF
PIN (S/N: MWP1-UP)
PART OF 308-0147 GENERATOR GP - HYDRAULIC
NOTE					PART NAME							TABLE REFERENCE
	REFERENCE NUMBER	ILLUSTRATION NUMBER	PART NUMBER	QTY	1	2	3	4	5	6	(Product Level)
	1	10	160-2756	1	VALVE - NEEDLE
	2	10	160-2773	1	RETAINER
	3	10	160-3507	1	VALVE GP - FLOW CONTROL
	4	10	160-3508	1	SPRING
	5	10	170-5715	2	SEAL-O-RING
	6	10	160-3511	1	VALVE GP - RELIEF
	7	10	160-3512	1	VALVE GP - NEEDLE
	8	10	160-3513	1	VALVE GP - SOLENOID
	9	10	160-3514	1	COIL AS
	10	10	160-3516	1	KIT - SEAL
	11	10	160-2755	1	VALVE GP - CHECK
	12	10	180-7106	1	VALVE GP - SOLENOID
	13	10	180-7107	1	COIL
	14	10	180-7108	1	PLUG - ORIFICE
	15	10	9S-8002	1	PLUG-O-RING
	16	10	9S-8005	5	PLUG-O-RING
	17	10	9S-8008	2	PLUG-O-RING
	18	10	184-1291	2	CONNECTOR
M - METRIC PART

Illustration 10	g01537196

251-8483 MOTOR GP - HYDRAULIC GENERATOR

Table 14

HYDRAULIC SYSTEM
251-8483 MOTOR GP - HYDRAULIC GENERATOR
PIN (S/N: MWP1-UP)
PART OF 308-0147 GENERATOR GP - HYDRAULIC
NOTE					PART NAME							TABLE REFERENCE
	REFERENCE NUMBER	ILLUSTRATION NUMBER	PART NUMBER	QTY	1	2	3	4	5	6	(Product Level)
	1	11	095-0940	1	RING - RETAINING
	2	11	253-3458	1	COVER
	3	11	8U-2564	1	SEAL
	4	11	253-3462	1	SEAL-O-RING
	5	11	117-8183	1	RING
	6	11	117-8801	1	SEAL-O-RING
	7	11	179-0202	4	BOLT (M12X1.7X65 - MM)
M - METRIC PART

Illustration 11	g01537593

289-3972 CONTROL GP - HYDRAULIC GENERATOR

Table 15

HYDRAULIC SYSTEM
289-3972 CONTROL GP - HYDRAULIC GENERATOR
PIN (S/N: MWP1-UP)
PART OF 308-0147 GENERATOR GP - HYDRAULIC
NOTE					PART NAME							TABLE REFERENCE
	REFERENCE NUMBER	ILLUSTRATION NUMBER	PART NUMBER	QTY	1	2	3	4	5	6	(Product Level)
	1		3S-2093	1	STRAP - CABLE
	2		6I-1418	4	SPACER (8.2X12.7X28.7 - MM THK)
	3		7K-1181	5	STRAP - CABLE
	4		8T-9655	8	MOUNT - ISOLATION
	5		113-8492	1	FUSE
	6		124-3548	2	FUSE
	7		160-3580	1	HANDLE
	8		160-3581	1	SHAFT
	9		171-4667	1	COVER
	10		173-5444	2	STOP
	11		178-3339	24	SCREW (8-32x0.5 - IN)
	12		189-2512	1	PLATE
	13		262-1408	1	CONTROL GP - UNPROGRAMMED
	14		288-3741	1	WIRE AS
	15		288-3743	1	WIRE AS
	16		288-3745	1	CABLE AS
	17		288-3749	1	HARNESS AS
	18		288-3753	1	BRACKET AS
	19		288-5507	1	PLATE AS
	20		289-3973	1	ENCLOSURE AS
	21		289-3974	1	PANEL AS
	22		291-8372	1	MONITOR
	23		304-5304	1	SENSOR
	24		304-5312	1	SENSOR
	25		308-2168	1	BOARD - CIRCUIT
	26		317-4258	1	RAIL - MOUNTING
	27		032-4000	4	SCREW (6-32X0.5 IN)
	28		095-0736	2	SCREW - MACHINE (M5X0.8X10 - MM)
	29		095-0741	2	SCREW - MACHINE (M6X1 - THD)
	30		132-3665	6	SPACER
	31		132-5789	2	CLIP
	32		160-3579	1	SWITCH
	33		160-3596	1	RESISTOR
	34		160-3600	4	RELAY
	35		160-3603	1	RELAY
	36		160-3604	1	RELAY
	37		160-3606	1	CONNECTOR AS
	38		173-5433	1	BASE
	39		173-5462	1	RESISTOR
	40		178-3341	4	SCREW
	41		180-7047	1	HARNESS AS - POWER
	42		180-7093	1	CONNECTOR
	43		222-6983	2	HEAT SINK
	44		263-6556	1	STUD
	45		263-6557	1	STUD
	46		3C-3681	4	NUT (M6X1.0)
	47		3K-6881	2	SCREW - MACHINE (1/4-20X0.625 - IN)
	48		4B-4863	6	WASHER (4.7X11.1.2 - MM THK)
	49		5C-2890	4	NUT (M6X1 - THD)
	50		5C-7261	5	NUT (M8X1.25 - THD)
	51		5C-9553	4	BOLT (M6X1X16 - MM))
	52		5P-0537	4	WASHER - HARD (7.2X14.5X2 - MM THK)
	53		5P-4116	5	WASHER - HARD (8.8X20.5X2 - MM THK)
	54		5P-8441	1	GROMMET
	55		6V-5210	2	SCREW - MACHINE (M4X0.7X10 - MM)
	56		8C-4667	4	SPACER
	57		8C-8514	8	SCREW - MACHINE (8-32X0.375 - IN)
	58		8T-4121	3	WASHER - HARD (11X21X25 - MM THK)
	59		8T-6411	4	SCREW - MACHINE (M6X1X12 - MM)
	60		8T-6912	4	BOLT (M8X1.25X50 - MM)
	61		9N-0869	4	WASHER - HARD (8.8X25.5X2 - MM THK)
	62		9S-2011	2	SCREW - MACHINE (1/4-20X0.5 - IN)
	63		9X-8256	8	WASHER (6.6X12X2 - MM THK)
	64		9X-8917	4	SCREW - MACHINE (4-40X9.52 - IN)
	65		9P-7951	4	COMPOUND - JOINT
M - METRIC PART

·

·

179-3625 PUMP GP - GEAR

Table 16

HYDRAULIC SYSTEM
179-3625 PUMP GP - GEAR
PIN (S/N: MWP1-UP)
PART OF 291-9591 INSTALLATION AR
NOTE					PART NAME							TABLE REFERENCE
	REFERENCE NUMBER	ILLUSTRATION NUMBER	PART NUMBER	QTY	1	2	3	4	5	6	(Product Level)
	1	12	4T-9300	3	BUSHING - TERMINAL
	2	12	136-9623	1	GEAR - DRIVE
	3	12	6J-2386	2	DOWEL
	4	12	133-6578	1	SEAL-O-RING
	5	12	4T-8729	2	PLATE
	6	12	4T-9426	1	PLATE
	7	12	8T-8917	8	BOLT (1/2-13X1.25 - IN)
	8	12	136-9624	1	KIT - SEAL
	9	12	4T-9176	1	GEAR
	10	12	136-9621	1	FLANGE AS
	11	12	4T-9425	1	PLATE
	12	12	137-0193	1	BODY AS
	13	12	4T-9299	1	BUSING - TERMINAL
M - METRIC PART

Illustration 12	g01522797

191-5537 DRIVE GP - AUXILIARY PUMP

Table 17

HYDRAULIC SYSTEM
191-5537 DRIVE GP - AUXILIARY PUMP
PIN (S/N: MWP1-UP)
PART OF 291-9591 INSTALLATION - AR
NOTE					PART NAME							TABLE REFERENCE
	REFERENCE NUMBER	ILLUSTRATION NUMBER	PART NUMBER	QTY	1	2	3	4	5	6	(Product Level)
	1	13	129-7857	1	GASKET
	2	13	173-3406	1	SHAFT
	3	13	173-3436	1	COVER
	4	13	177-2585	1	COVER
	5	13	191-5539	1	SHAFT
	6	13	191-5540	1	GEAR
	7	13	191-5541	1	COVER
	8	13	191-5601	2	BEARING
	9	13	204-2764	1	BODY
	10	13	094-1875	2	DOWEL
	11	13	095-1680	1	SEAL-O-RING
	12	13	096-0121	1	SEAL-O-RING
	13	13	099-2096	2	BALL BEARING
	14	13	101-7402	8	BOLT - SOCKET HEAD (M12X1.75X30 - MM)
	15	13	3J-1907	1	SEAL-O-RING
	16	13	8T-4189	2	BOLT (M8X1.25X20 - MM)
	17	13	8T-4192	2	BOLT (M12X1.75X25 - MM)
	18	13	8T-5049	1	SEAL-O-RING
	19	13	9S-4191	1	PLUG-O-RING
M - METRIC PART

Illustration 13	g01522917

291-9613 ENCLOSE GP - GENERATOR

Table 18

HYDRAULIC SYSTEM
291-9613 ENCLOSE GP - GENERATOR
PIN (S/N: MWP1-UP)
PART OF 291-9591 INSTALLATION AR
NOTE					PART NAME							TABLE REFERENCE
	REFERENCE NUMBER	ILLUSTRATION NUMBER	PART NUMBER	QTY	1	2	3	4	5	6	(Product Level)
	1	14	255-9378	1	COVER AS
	2	14	291-9379	1	TREAD
	3	14	291-9614	1	BOX AS
	4	14	137-2255	5	BOLT (M8X1.25X8 - MM)
	5	14	208-9310	4	BOLT - FLANGE HEAD
	6	14	5C-7261	5	NUT (M8X1.25 - THD)
	7	14	5P-4116	5	WASHER - HARD (8.8X20.5X2 - MM THK)
	8	14	8T-4139	4	BOLT (M12X1.75X30 - MM)
	9	14	8T-4223	6	WASHER - HARD (13.5X25.5X3 - MM THK)
	10	14	8T-4956	2	BOLT (M12X1.75X35 - MM)
M - METRIC PART

Illustration 14	g01597119

291-9559 WIRING GP - HYDRAULIC GENERATOR

Table 19

HYDRAULIC SYSTEM
291-9559 WIRING GP - HYDRAULIC GENERATOR
PIN (S/N: MWP1-UP)
PART OF 291-9591 INSTALLATION AR
NOTE					PART NAME							TABLE REFERENCE
	REFERENCE NUMBER	ILLUSTRATION NUMBER	PART NUMBER	QTY	1	2	3	4	5	6	(Product Level)
	1	17	113-8490	1	FUSE
	2	17	145-8054	1	HARNESS AS - MONITOR
	3	16	149-5050	2	RELAY
	4	17	161-3128	2	RELAY
	5	16	166-4705	1	HARNESS AS - CONTROL
	6	17	257-2823	1	COVER
	7	17	259-4884	1	BRACKET AS
	8	17	276-5401	1	HARNESS AS - WIRING
	9	16	291-9560	1	WIRE AS
	10	16	291-9563	1	HARNESS AS - FRONT CHASSIS
	11	17	291-9564	1	HARNESS AS - FRONT CHASSIS
	12	17	291-9565	1	HARNESS AS - FRONT CHASSIS
	13	16	291-9566	1	HARNESS AS - CONTROL
	14	16	291-9600	1	HARNESS AS - POWER
	15	15	316-2491	1	BRACKET
	16	16	5C-2890	2	NUT (M6X1 - THD)
	17	15	5C-8312	2	NUT (M4X0.7 - THD)
	18	17	9X-2042	3	SCREW - TRUSS HEAD (M6X1X12 - MM)
	19	16	9X-8256	2	WASHER (6.6X12.2 - MM THK)
	20	17	7N-2353	1	SWITCH AS - TOGGLE
M - METRIC PART

Illustration 15	g01546335

Illustration 16	g01694237

Illustration 17	g01694234

261-4485 LIGHTING GP - CHASSIS

Table 20

HYDRAULIC SYSTEM
261-4485 LIGHTING GP - CHASSIS
PIN (S/N: MWP1-UP)
PART OF 291-9591 INSTALLATION AR
NOTE					PART NAME							TABLE REFERENCE
	REFERENCE NUMBER	ILLUSTRATION NUMBER	PART NUMBER	QTY	1	2	3	4	5	6	(Product Level)
	1	18	3N-9116	1	STRIP - TERMINAL
	2	18	3S-2093	4	STRAP - CABLE
Y	3	18	153-2523	1	LAMP GP - FLOOD							21
	4	18	262-7682	1	HARNESS AS - LIGHTING
	5	18	6V-9672	2	SCREW - MACHINE (M4X0.7X16 - MM)
	6	18	9B-7233	2	LOCKWASHER
M - METRIC PART

Illustration 18	g01526075

153-2523 LAMP GP - FLOOD

Table 21

HYDRAULIC SYSTEM
153-2523 LAMP GP - FLOOD
PIN (S/N: MWP1-UP)
PART OF 261-4485 LIGHTING GP - CHASSIS
Refer to Parts Manual, SEBP4514, "330D L Hydraulic Excavator" for the parts list.

·

·

291-9588 HANDRAIL GP

Table 22

HYDRAULIC SYSTEM
291-9588 HANDRAIL GP
PIN (S/N: MWP1-UP)
PART OF 291-9591 INSTALLATION AR
NOTE					PART NAME							TABLE REFERENCE
	REFERENCE NUMBER	ILLUSTRATION NUMBER	PART NUMBER	QTY	1	2	3	4	5	6	(Product Level)
	1	19	177-5879	1	CLAMP
	2	19	256-6113	1	STEP AS
	3	19	282-5380	1	GROMMET
	4	19	291-9587	1	HANDRAIL AS
	5	19	291-9601	1	HANDRAIL AS
	6	19	8T-4192	17	BOLT (M12X1.75X25 - MM)
	7	19	8T-4223	17	WASHER - HARD (13.5X25.5.X3 - MM THK)
M - METRIC PART

Illustration 19	g01725434

245-1741 WIRING GP - CONVERTER

Table 23

HYDRAULIC SYSTEM
245-1741 WIRING GP - CONVERTER
PIN (S/N: MWP1-UP)
PART OF 291-9591 INSTALLATION AR
Refer to Parts Manual, SEBP4514, "330D L Hydraulic Excavator" for the parts list.

·

·

272-3274 PANEL & MTG GP - CIRCUIT BREAKER

Table 24

HYDRAULIC SYSTEM
272-3274 PANEL & MTG GP - CIRCUIT BREAKER
PIN (S/N: MWP1-UP)
PART OF 291-9591 INSTALLATION AR
NOTE					PART NAME							TABLE REFERENCE
	REFERENCE NUMBER	ILLUSTRATION NUMBER	PART NUMBER	QTY	1	2	3	4	5	6	(Product Level)
Y	1	20	274-5081	1	PANEL GP - CIRCUIT BREAKER							25
	2	20	8T-4121	4	WASHER - HARD (11X21X2.5 - MM THK)
	3	20	8T-4137	4	BOLT (M10X1.5X20 - MM)
M - METRIC PART

Illustration 20	g01526514

274-5081 PANEL GP - CIRCUIT BREAKER

Table 25

HYDRAULIC SYSTEM
274-5081 PANEL GP - CIRCUIT BREAKER
PIN (S/N: MWP1-UP)
PART OF 272-3274 PANEL & MTG GP - CIRCUIT BREAKER
NOTE					PART NAME							TABLE REFERENCE
	REFERENCE NUMBER	ILLUSTRATION NUMBER	PART NUMBER	QTY	1	2	3	4	5	6	(Product Level)
	1	21	3E-8320	1	PLATE
	2	21	7N-0719	1	SWITCH AS - DISCONNECT
	3	21	9G-2758	1	LOCKOUT AS - SWITCH
	4	21	125-1302	1	SWITCH AS - MAGNETIC
	5	21	216-4970	1	CIRCUIT BREAKER AS (120 AMPERE)
	6	21	234-1035	1	CABLE AS
	7	21	234-1037	1	WIRE AS
	8	21	234-1038	1	WIRE AS
	9	21	238-1506	1	COVER
	10	21	238-2279	1	BAR - BUS
	11	21	238-2280	1	WIRE AS
	12	21	251-0303	1	CABLE AS
	13	21	251-0304	1	CABLE AS
	14	21	256-0806	1	WIRE AS
	15	21	274-5082	1	BRACKET AS
	16	21	275-2631	1	BLOCK - TERMINAL
	17	21	068-4209	2	SCREW (8-32X0.75 - IN)
	18	21	096-6166	2	WASHER - HARD (4.5X9X1 - MM THK)
	19	21	171-2210	2	CIRCUIT BREAKER AS (80 AMPERE)
	20	21	5C-9553	6	BOLT (M6X1X16 - MM)
	21	21	5P-4115	4	WASHER - HARD (7.2X19X2 - MM THK)
	22	21	6N-9349	1	CIRCUIT BREAKER AS (30 AMPERE)
	23	21	6V-5645	6	SCREW - MACHINE (10-32X0.87 - IN)
	24	21	8T-0328	6	WASHER - HARD (5.5X10X1 - MM THK)
	25	21	8T-4171	4	BOLT (M6X1X12 - MM)
	26	21	8T-4970	4	BOLT (M6X1X14 - MM)
	27	21	9X-8256	12	WASHER (6.6X12X2 - MM THK)
M - METRIC PART

Illustration 21	g01526600

272-5821 COVER GP - ACCESS

Table 26

HYDRAULIC SYSTEM
272-5821 COVER GP - ACCESS
PIN (S/N: MWP1-UP)
PART OF 291-9591 INSTALLATION AR
NOTE					PART NAME							TABLE REFERENCE
	REFERENCE NUMBER	ILLUSTRATION NUMBER	PART NUMBER	QTY	1	2	3	4	5	6	(Product Level)
	1	22	4I-0117	1	FASTNER
	2	22	4I-0118	1	HOOK AS
	3	23	194-3251	2	BUMPER
	4	23	255-3510	1	BRACKET AS
	5	23	255-3511	1	BRACKET AS
	6	23	255-3512	1	BRACKET
	7	23	255-3513	1	BRACKET
	8	23	255-3514	1	SUPPORT AS
	9	23	272-7210	1	HINGE AS
	10	23	285-6697	1	SPRING
	11	22	286-1076	1	HANDLE AS
	12	22	300-3716	1	COVER AS
	13	23	5C-7883	4	BOLT - SOCKET HEAD (M6X1X16 - MM)
	14	23	6V-7743	4	LOCKNUT (M6X1 - THD)
	15	23	7J-5925	1	COTTER
	16	23	7X-2562	2	BOLT (M20X2.5X45 - MM)
	17	23	7Y-2916	1	PIN - CLEVIS
	18	23	8T-4121	15	WASHER - HARD (11X21X2.5 - MM THK)
	19	23	8T-4123	2	WASHER - HARD (22X35X3.5 - MM THK)
	20	23	8T-4133	6	NUT (M10X1.5 - THD)
	21	23	8T-4136	7	BOLT (M10X1.5X25 - MM)
	22	23	8T-4184	4	BOLT (M12X1.75X45 - MM)
	23	23	8T-4186	2	BOLT (M10X1.5X40 - MM)
	24	22	8T-4189	2	BOLT (M8X1.25X20 - MM)
	25	22	8T-4200	1	BOLT (M8X1.25X16 - MM)
	26	23	8T-4205	4	WASHER - HARD (7.2X14.5X2 - MM THK)
	27	23	8T-4223	6	WASHER - HARD (13.5X25.5X3 - MM THK)
	28	22	8T-4224	6	WASHER - HARD (8.8X16X2 - MM THK)
	29	22	8T-4908	3	BOLT (M8X1.25X25 - MM)
M - METRIC PART

Illustration 22	g01546934

Illustration 23	g01546935

291-9581 FENDER & COVER GP

Table 27

HYDRAULIC SYSTEM
291-9581 FENDER & COVER GP
PIN (S/N: MWP1-UP)
PART OF 291-9591 INSTALLATION AR
NOTE					PART NAME							TABLE REFERENCE
	REFERENCE NUMBER	ILLUSTRATION NUMBER	PART NUMBER	QTY	1	2	3	4	5	6	(Product Level)
	1	24	236-3702	2	SPACER (15X35X11 - MM THK)
	2	24	236-3703	2	WASHER (25X35X4 - MM THK)
	3	24	291-9580	1	COVER AS
	4	24	5P-1075	2	WASHER - HARD (10X22.5X3 - MM THK)
	5	24	8T-4195	2	BOLT (M10X1.5X30 - MM)
M - METRIC PART

Illustration 24	g01725453

291-9599 LINES GP - AUXILIARY HYDRAULIC

Table 28

HYDRAULIC SYSTEM
291-9599 LINES GP - AUXILIARY HYDRAULIC
PIN (S/N: MWP1-UP)
PART OF 291-9591 INSTALLATION AR
NOTE					PART NAME							TABLE REFERENCE
	REFERENCE NUMBER	ILLUSTRATION NUMBER	PART NUMBER	QTY	1	2	3	4	5	6	(Product Level)
	1	26	126-1913	1	PLATE
	2	26	131-9750	1	SCREEN AS
	3	26	146-5790	1	FLANGE
	4	26	170-8553	4	BOLT - SOCKET HEAD (M12X1.75X40 - MM)
	5	26	260-7840	1	FLANGE
	6	25	260-7842	1	SUPPORT AS
	7	25	274-5221	1	TUBE AS
	8	25	274-5222	1	TUBE AS
	9	26	275-1610	1	GROMMET
	10	25	279-6070	1	HOSE AS
	11	25	279-6071	1	HOSE AS
	12	25	291-9602	1	BRACKET AS
	13	25	291-9619	1	HOSE AS
	14	25	142-0038	2	ELBOW
	15	26	148-8352	3	ELBOW AS
	16	25	148-8429	1	TEE AS
	17	26	1P-4578	2	FLANGE - HALF
	18	26	1P-4579	2	FLANGE - HALF
	19	26	3J-5696	4	PIPE
	20	26	4J-0522	2	SEAL-O-RING
	21	26	4J-0524	1	SEAL-O-RING
	22	26	4J-0527	1	SEAL-O-RING
	23	26	4J-5267	1	SEAL-O-RING
	24	26	5I-8748	1	SPACER
	25	25, 26	5K-9090	5	SEAL-O-RING
	26	26	5P-1075	1	WASHER - HARD (10.2X22.5X3 - MM THK)
	27	26	5P-7468	1	CLIP
	28	26	5P-7469	1	CLIP
	29	25	5P-7470	1	CLIP
	30	25	5P-7471	1	CLIP
	31	25	5P-8182	1	GROMMET
	32	26	6V-6707	1	SEAL-O-RING
	33	25	7G-5984	1	CLIP
	34	25	7G-5985	1	CLIP
	35	25	7G-5986	1	GROMMET
	36	26	8T-1889	6	CLIP
	37	26	8T-1890	6	CLIP
	38	26	8T-2525	1	GROMMET
	39	25,26	8T-4121	23	WASHER- HARD (11X21X2.5 - MM THK)
	40	25	8T-4136	11	BOLT (M10X1.5X25 - MM)
	41	25	8T-4139	3	BOLT (M12X1.75X30 - MM)
	42	26	8T-4182	4	BOLT (M10X1.5X45 - MM)
	43	26	8T-4184	4	BOLT (M12X1.75X45 - MM)
	44	26	8T-4195	5	BOLT (M10X1.5X30 - MM)
	45	26	8T-4196	4	BOLT (M10X1.5X35 - MM)
	46	25,26	8T-4223	7	WASHER - HARD (13.5X25.5X3 - MM THK)
	47	26	8Y-3925	1	BOSS (3/8-16X1.2 - IN)
M - METRIC PART

Illustration 25	g01590643

Illustration 26	g01593433

259-7598 CONTROL & MTG GP - JOYSTICK

Table 29

HYDRAULIC SYSTEM
259-7598 CONTROL & MTG GP - JOYSTICK
PIN (S/N: MWP1-UP)
PART OF 291-9591 INSTALLATION AR
NOTE					PART NAME							TABLE REFERENCE
	REFERENCE NUMBER	ILLUSTRATION NUMBER	PART NUMBER	QTY	1	2	3	4	5	6	(Product Level)
Y	1	27	259-0534	1	CONTROL GP - JOYSTICK
Y	2	27	259-0535	1	CONTROL GP - JOYSTICK
	3	27	6V-7357	6	BOLT (M6X1X25 - MM)
	4	27	9X-8256	6	WASHER (6.6X12X2 - MM THK)
M - METRIC PART

Illustration 27	g01598113

297-0534 CONTROL GP - JOYSTICK

Table 30

HYDRAULIC SYSTEM
297-0534 CONTROL GP - JOYSTICK
PIN (S/N: MWP1-UP)
PART OF 259-7598 CONTROL & MTG GP - JOYSTICK
NOTE					PART NAME							TABLE REFERENCE
	REFERENCE NUMBER	ILLUSTRATION NUMBER	PART NUMBER	QTY	1	2	3	4	5	6	(Product Level)
	1	28	6K-0806	1	STRAP - CABLE
Y	2	28	260-2109	1	CONTROL GP - HANDLE
Y	3	28	297-0589	1	VALVE GP - PILOT
M - METRIC PART

Illustration 28	g01600953

260-2109 CONTROL GP - HANDLE

Table 31

HYDRAULIC SYSTEM
260-2109 CONTROL GP - HANDLE
PIN (S/N: MWP1-UP)
PART OF 297-0534 CONTROL GP - JOYSTICK
NOTE					PART NAME							TABLE REFERENCE
	REFERENCE NUMBER	ILLUSTRATION NUMBER	PART NUMBER	QTY	1	2	3	4	5	6	(Product Level)
	1	29	7Y-8463	1	NUT (M14X2 - THD)
	2	29	113-2532	1	PIN
	3	29	260-2111	1	LEVER
Y	4	29	297-4589	1	CONTROL GP - HANDLE
	5	29	305-0332	1	BOOT
M - METRIC PART

Illustration 29	g01718836

297-4589 CONTROL GP - HANDLE

Table 32

HYDRAULIC SYSTEM
297-4589 CONTROL GP - HANDLE
PIN (S/N: MWP1-UP)
PART OF 260-2109 CONTROL GP - HANDLE
NOTE					PART NAME							TABLE REFERENCE
	REFERENCE NUMBER	ILLUSTRATION NUMBER	PART NUMBER	QTY	1	2	3	4	5	6	(Product Level)
	1	30	144-1636	6	PIN
	2	30	247-2693	1	RECEPTACLE AS
M - METRIC PART

Illustration 30	g01718863

297-0589 VALVE GP - PILOT

Table 33

HYDRAULIC SYSTEM
297-0589 VALVE GP - PILOT
PIN (S/N: MWP1-UP)
PART OF 297-0534 CONTROL GP - JOYSTICK
NOTE					PART NAME							TABLE REFERENCE
	REFERENCE NUMBER	ILLUSTRATION NUMBER	PART NUMBER	QTY	1	2	3	4	5	6	(Product Level)
	1	31	095-1586	4	SEAL - O - RING
	2	31	4I-6365	1	JOINT
	3	31	094-0876	4	SEAL
	4	31	096-1628	4	PLUG
	5	31	099-6137	4	WASHER (6X9X0.2 - MM THK)
	6	31	118-4086	4	ROD
	7	31	118-4087	4	SPRING
	8	31	131-5915	1	NUT - SPECIAL
	9	31	165-9431	1	PLATE
	10	31	165-9435	2	SEAT
	11	31	165-9436	2	SEAT
	12	31	165-9438	1	PLATE
	13	31	165-9442	2	SPRING
	14	31	165-9443	2	SEAT - SPRING
	15	31	165-9444	2	SEAT - SPRING
	16	31	165-9460	2	SPRING
	17	31	165-9461	4	SPRING
	18	31	171-0087	1	BELLOWS
M - METRIC PART

Illustration 31	g01720176

General Information

The hydraulic system for the hydraulic generator includes the following components.

• A generator set that is powered by a hydraulic motor

• A magnet

• Operator Controls

• A fixed displacement pump for the hydraulic generator

A gear pump supplies the hydraulic oil in order to turn the hydraulic motor. The generator set produces the required voltage for the magnet.

Operation Section

Operator's Compartment

The details of the Engine Speed Control switch and of the travel control switch are not described in this section. See the appropriate topics in the Operation and Maintenance Manual for details about these components.

Illustration 32	g00708463
Typical Example (1) Left console (2) Hydraulic lockout control (3) Left travel pedal (4) Right travel pedal (5) Left joystick (6) Left travel lever (7) Right travel lever (8) Service hour meter (9) Monitor (10) Magnet control and monitor panel (11) Right joystick (12) Right console (13) Grapple/magnet switch (14) Backup controls (15) Operator's seat

Safety Information

Electrical Shock Hazard

Show/hide table

Before servicing, turn generator disconnect switch to the OFF position. Failure to do so could result in serious injury or death.

Show/hide table

Know the maximum height and the maximum reach of your machine. Serious injury or death by electrocution can occur if the machine or the work tools are not kept a safe distance from electrical power lines. Keep a distance of at least 3000 mm (118 inch) plus an additional 10 mm (0.4 inch) for each 1000 volts over 50000 volts.

Illustration 33	g00709188
This warning label is positioned on the hydraulic generator control panel in two places.

Illustration 34	g00788652
(1) Outside of the hydraulic generator control panel (2) Inside of the hydraulic generator control panel

The warning label that is shown in Illustration 34 is located in two places on the hydraulic generator control panel. The hydraulic generator for the magnet is located inside the right front enclosure.

Operating Techniques

Information on Operating Techniques

Show/hide table

Know the maximum height and the maximum reach of your machine. Serious injury or death by electrocution can occur if the machine or the work tools are not kept a safe distance from electrical power lines. Keep a distance of at least 3000 mm (118 inch) plus an additional 10 mm (0.4 inch) for each 1000 volts over 50000 volts.

For safety, one of the following may require a greater distance:

• Local codes

• State codes

• Requirements of the job site

Show/hide table

NOTICE
When swinging into any object, do not use the object to stop the swinging motion. Inspect the machine for damage if the boom is swung into a structure or an object. Repeated stopping of the swing by an object can cause structural damage. With certain boom-stick-work tool combinations, the work tool can hit the cab or front of the machine. Always check for interference when first operating a new work tool. Whenever the tracks of the machine raise off the ground while operating, lower the machine back to the ground smoothly. DO NOT DROP OR CATCH IT WITH THE HYDRAULICS. Damage to the machine can result.

With certain combinations of implements, the third pedal can have different functions. Always check the function of the third pedal before you use the third pedal.

Know the location of any power cables and any utility main. Mark the locations clearly before you operate the machine.

Consult your Caterpillar dealer for special attachments that are available for use in various applications.

Move the machine whenever the position for operation is not efficient. The machine can be moved forward or backward during the operating cycle.

Use a comfortable travel speed while you operate the machine.

Operating efficiency can be increased by using more than one machine control to perform a task.

Never swing a load over a truck cab or workers.

Position the truck so that material can be loaded from the rear of the truck or from the side of the truck. Load the truck evenly so that the rear axles are not overloaded.

Select an work tool that is correct for the work to be performed. Implements that do not match the work slow down the cycle.

Restricted Operation

Illustration 35	g00788680

Do not use the swing force to perform the following operations:

• Pushing material

• Separating material

• Demolition

Do not swing the machine while the work tool is in the pile of material.

These operations will damage the boom, the stick and the work tool and the operations will reduce the life of the equipment.

Illustration 36	g00788704

Do not use the dropping force of the work tool as a hammer. This will bring excessive force on the rear of the machine. Possible damage to the work tool and/or the machine could result.

Illustration 37	g00788707

If the cylinder is operated to the end of the stroke during operations, excessive force will occur on the stopper on the inside of the cylinder. This will reduce the life of the cylinder. To avoid this problem, always leave a small margin of play when the cylinder is operated.

Illustration 38	g00788721

Do not use the front structures and the work tool to compact loose materials. Slowly lower the work tool to the loose material and slowly lift the material. Repeated cycles of rapid acceleration and abrupt stopping of the front structures and attached work tools significantly reduces the life of the upper structures. Analysis of this practice with a strain gauge indicates that the life of the structure can be reduced by as much as four times.

Illustration 39	g00788732

While the work tool is in the material pile, do not use the travel force for any movement of the pile. This operation will cause excessive force on the rear of the machine.

Illustration 40	g00788760

Do not use the dropping force of the rear of the machine for moving material. This operation will damage the machine.

Operating Precaution

Illustration 41	g00788778

When you work over a bank do not lower the boom so the bottom side of the boom touches the ground.

When you work over a bank, do not allow the boom to interfere with the wheels.

Operation of the Excavator that is Equipped with a Magnet

Show/hide table

To prevent injury, do not exceed the rated load capacity of the machine. If the machine is not on level ground, load capacities will vary.

Show/hide table

NOTICE
Damage to the work tool or linkage could result if the slings are placed incorrectly.

Short slings will prevent excessive load swing.

Note: There may be local government regulations about the use of excavators for the lifting of heavy objects. Please observe those regulations.

Illustration 42	g00788796

An unstable condition can exist if a load exceeds the machine load rating or if a heavy load is swung over an end or over a side.

Illustration 43	g00788800

The most stable lifting position is over a corner of the machine.

Illustration 44	g00788804

For the best stability, carry a load close to the machine and to the ground.

Illustration 45	g00788807

The lift capacity decreases as the distance from the swing centerline increases. Rotate the upper frame by 90 degrees relative to the undercarriage when the machine is working in a stationary application. This will evenly load the swing bearing.

Operation of the Magnet

Show/hide table

Never connect or disconnect the magnet unless the engine is shut down and the main switch for the generator is in the OFF position. Failure to follow this procedure may result in personal injury or death.

Show/hide table

The grapple or the magnet can swing in all directions. Personal injury can result if the attachment swings into the cab or a person in the work area.

Show/hide table

Before making any adjustments to the generator the engine must be shut off and the main disconnect switch on the controller must be in the off position. Personal injury can occur. Close all controller panel doors before the generator is started. Personal injury can occur. Never handle the leads to the magnet unless the generator is stopped and the main disconnect switch on the controller is in the off position. Personal injury can occur.

Show/hide table

Failure to comply to the rated load can cause personal injury or work tool damage. Review the rated load of a particular work tool before performing any operation. Make adjustments to the rated load as necessary for non standard configurations.

Show/hide table

To prevent injury, do not exceed the rated load capacity of the machine. If the machine is not on level ground, load capacities will vary.

Show/hide table

Know the maximum height and the maximum reach of your machine. Serious injury or death by electrocution can occur if the machine or the work tools are not kept a safe distance from electrical power lines. Keep a distance of at least 3000 mm (118 inch) plus an additional 10 mm (0.4 inch) for each 1000 volts over 50000 volts.

Show/hide table

Do not leave the controls unattended while a load is suspended. No person shall be permitted to stand or pass under a suspended load or work tool. A suspended load or work tool may fall causing injury or death.

Show/hide table

Never operate a magnet with a direct electrical short to case. Any person making contact with such a magnet could receive an electrical shock, resulting in injury or death.

Note: All personnel should stay clear of the magnet during operation of the magnet.

Do not exceed the rated duty cycle of the magnet. Exceeding the rated duty cycle reduces lifting capacity because of excessive heat buildup in the magnet.

The following formula defines the duty cycle:

Table 34

Magnet ON (duration)	×	100
Magnet OFF (duration)	+	Magnet ON (duration)

The answer is expressed as a percent with a maximum time of ten minutes (duration) for magnet ON in order to avoid overheating the magnet. To maximize the efficiency of your magnet, always turn off the magnet when the magnet is not active. Caterpillar only recommends the use of magnets with a duty cycle of 75 percent with Caterpillar machines.

The generator supplies power to the magnet when the grapple/magnet switch on the right console is turned on.

Refer to the "Work Tool and Swing Control" section for information regarding the switch for the magnet. Refer to "Control Levers" section for information about using the joystick controls for the magnet.

Magnet Generator

The hydraulic generator motor drives the generator and the generator supplies power to the magnet. The generator is turned on and off by the position of the grapple/magnet switch. The disconnect switch for the hydraulic generator controller is mounted on the door. The hydraulic generator controller routes input power to the generator. The hydraulic generator controller also routes the output power from the generator to the magnet.

The generator generates power under the following conditions:

• The switch for the magnet is in the ON position.

• The engine is running.

• The generator circuit has not detected a fault.

The generator, a hydraulic motor, and the hydraulic generator controller are mounted on the same subframe. The hydraulic generator controller maintains the generator output at a preset level during operation of the magnet.

If the generator overheats, turn off the generator. Allow the system to cool. Make sure that the magnet is the proper size for the output of the generator. Check for a short in the system. Make sure that the duty cycle is less than 75 percent.

If there are any problems with the generator, consult your Caterpillar dealer.

Inspecting the Magnet

Show/hide table

Never connect or disconnect the magnet unless the engine is shut down and the main switch for the generator is in the OFF position. Failure to follow this procedure may result in personal injury or death.

Show/hide table

Before making any adjustments to the generator the engine must be shut off and the main disconnect switch on the controller must be in the off position. Personal injury can occur. Close all controller panel doors before the generator is started. Personal injury can occur. Never handle the leads to the magnet unless the generator is stopped and the main disconnect switch on the controller is in the off position. Personal injury can occur.

1. Park the machine on a firm, level surface. Lower the magnet to the ground. Move the hydraulic lockout control to the LOCKED position.

2. Turn off the engine. Turn the battery disconnect switch to the OFF position.

3. Attach a "Do Not Operate" warning tag or a similar warning tag to the start switch or to the controls. These warning tags (Special Instruction, SEHS7332) are available from your Caterpillar dealer.

4. Turn the main disconnect switch for the generator to the OFF position.

5. Inspect all chain links for wear. Check the diameter of the worn chain links. If the diameter of any worn chain link is less than 80 percent of the diameter of the new chain links, replace the chain. Never weld on a worn chain link in an attempt to repair the worn chain link.

6. Inspect all chain pins. If the diameter of any worn chain pins is less than 80 percent of the diameter of the new chain pins, replace the chain pins.

7. Inspect cotter pins, plates, washers, hooks, latches, shackles, and clevises. Make sure that these components are in good condition. If any of these components are worn or damaged, replace the components.

8. Inspect the case of the magnet for cracks. Immediately repair any cracks.

9. Inspect the condition of all electrical cables and of all power cords. Look for cuts, for abrasions, and for other types of damage. Replace any suspect cables or suspect power cords.

10. Inspect the terminal box for any damaged component or for missing components. Replace any covers or plugs in order to prevent moisture from entering the terminal box. During repairs or inspection, dirt and foreign materials can enter the terminal box by accident. Dirt and foreign materials can retain moisture. Check for any buildup of dirt or of foreign materials in the area of the terminal box and clean up any buildup of dirt or of foreign materials.

Magnet Control and Monitor Panel

Illustration 46	g00274430

Illustration 47	g00789508

"MAGNET ON" (1) - If this indicator comes on, the magnet is energized.

"VOLTS FAULT" (2) - If this indicator comes on, the voltage is too high or the voltage is too low in order to properly operate the magnet. One or more of the following items could remedy the problem:

• Check the electrical connections.

• Inspect the generator field resistor.

• Check that the generator is operating at the correct speed (1750 RPM).

• Check the generator.

"OVER 75% D.C." (Duty Cycle) (3) - If this indicator comes on, the magnet is being operated more than 75 percent of the time.

"GEN HOT" (4) - If this indicator comes on, the generator is overheating. One or more of the following items could be the reason that the generator is overheating:

• The magnet is too large.

• There is a short or a ground in the system.

• The duty cycle is too high.

• The voltage is too high.

• There is insufficient airflow through the generator.

• The generator is damaged.

"+ GND FAULT" (5) - If this indicator comes on, the resistance to ground in the positive line has dropped below 50,000 ohms.

"- GND FAULT" (6) - If this indicator comes on, the resistance to ground in the negative line has dropped below 50,000 ohms.

"DROP TIME" (7) - The drop time is controlled by a potentiometer. To achieve the best drop time for a given magnet, set the drop time to "0". Lift the load and drop the load at consecutively higher settings until a clean drop is achieved. The potentiometer should be reset if the magnet is changed.

Work Tool and Swing Control

Grapple/Magnet Switch

Illustration 48	g00275805

The grapple/magnet switch is located on the right console. Remove cover (1) in order to gain access to the switch.

Illustration 49	g00275805

The grapple/magnet switch is located on the right console. Remove cover (1) in order to gain access to the switch.

Illustration 50	g00396438

Magnet OFF (3) - Move switch (2) to this position in order to turn off the power to the hydraulic generator controller.

Magnet ON (4) - Move switch (2) to this position in order to turn on the power to the hydraulic generator controller. When the generator is activated, the magnet can be used.

Magnet Control Levers

Before operating the magnet, make sure that the grapple/magnet switch is in the Magnet ON position. Refer to Illustration 50.

Illustration 51	g00107449

Illustration 52	g00737535

The machine control pattern is initially set at the factory to the SAE system, as shown. Refer to Illustration 52. The pattern on the left pertains to the left control lever and the pattern on the right pertains to the right control lever.

Stick Out (1) - Move the control lever to this position in order to move the stick outward.

Swing Right (2) - Move the control lever to this position in order to swing the upper structure to the right.

Stick In (3) - Move the control lever to this position in order to move the stick inward.

Swing Left (4) - Move the control lever to this position in order to swing the upper structure to the left.

Boom Lower (5) - Move the control lever to this position in order to lower the boom.

Boom Raise (7) - Move the control lever to this position in order to raise the boom.

HOLD (9) - When you release the control levers from any position, the control levers will return to the HOLD position. Movement of the upper structure will stop.

Two functions may be performed at the same time by moving a control lever diagonally.

Left Joystick

Illustration 53	g00737544

Magnet DROP (11) - Press the switch on the front of the left control lever in order to turn off the magnet.

Horn (12) - Press the lower switch on the top of the left control lever in order to activate the horn.

Right Joystick

Illustration 54	g01155099

AEC Switch (14) - Press the lower switch on the top of the right control lever in order to activate low engine speed. Press the switch again in order to activate high engine speed.

Magnet LIFT (15) - Press the switch on the front of the right control lever in order to turn on the magnet.

Maintenance Section

Hydraulic System Pressure Release

Release the pressure in the work tool hydraulic circuits (boom, stick and bucket) before any hydraulic lines or components are disconnected or removed.

1. Fully extend the stick cylinder rod.

2. Lower the boom until the attachment is flat on the ground.

3. Shut off the engine and place the key in the ON position.

4. Place the hydraulic lockout control in the UNLOCKED position.

5. Move the work tool control levers in all directions in order to relieve any pressure that might be present in the pilot system.

6. Return the key to the OFF position.

7. Slowly loosen the fill/vent plug on the hydraulic tank and release the pressure.

8. Tighten the fill/vent plug on the hydraulic tank to the specified torque.

9. The pressure in the system should now be released and lines and components can be removed.

Main Pumps

When the main pumps have been serviced or the hydraulic oil has been replaced, remove the air from the hydraulic system. Remove the air from the hydraulic system in the following manner:

Show/hide table

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, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Show/hide table

NOTICE
To avoid system damage, make sure that the hydraulic pump is properly filled with hydraulic oil before start-up.

Show/hide table



Illustration 55	g00339492
Pump Compartment (1) Vent plug

1. While the engine is stopped, remove vent plug (1) on the top of the main pump. Leave vent plug (1) out of the pump for several minutes until the main pumps are filled with hydraulic oil. After the pumps fill with oil, install the vent plug (1). Tighten vent plug (1) and start the engine. Place the engine at low idle position. Raise the boom and hold the boom in this position.

2. Stop the engine and slowly lower the boom until the tool is on the ground. The hydraulic tank will build pressure.

3. Slowly loosen vent plug (1) until oil begins to flow from the opening.

4. Tighten the vent plug to the specified torque.

Generator Maintenance

General Maintenance Information

Preventive maintenance requires regular inspection of the generator and accessories. The first inspection should be made after the generator has run for a short period of time. The generator is designed to provide power to a magnet. The generator provides 230 volts at the maximum nameplate amperage at a 75% duty cycle. The display for the operator in the cab will indicate if the duty cycle exceeds 75%. Magnets may overheat if the duty cycle exceeds 75%. The display for the operator in the cab will also indicate if the generator overheats.

Turn off the generator and allow the system to cool, if the generator overheats. Determine if the magnet is properly sized for the output of the generator.

Also, check for a short in the system, and confirm a duty cycle less than 75%.

Maintenance Interval Schedule for the Generator

Before performing any operation or maintenance procedures, ensure that the Safety Information, warnings, and instructions are read and understood.

To determine the maintenance intervals, use service hours or calendar time, which ever comes first.

Before each consecutive interval is performed, all of the maintenance requirements from the previous interval must be performed.

Perform the following maintenance procedures for every 1000 hours or for 6 months.

• Armature Check

• Brush Check

• Field Coil Check

• Generator Drive Coupling Check

Perform the following maintenance procedure for every 2000 hours or for 12 months. Replace the case drain filter on the hydraulic system for the generator. The filter is located inside the generator enclosure.

For bearing lubrication intervals, see Table 35.

Perform the maintenance procedure that follows every week:

• Walk-Around Inspection

Armature Check

Excessive loads will cause a noticeable odor that is the result of overheated varnish or burnt insulation. The commutator may eventually become blackened and pitted. The brushes may become burned. This overheating may be general and uniform. The source of the overload must be removed and the armature must be rewound or replaced.

An open circuit in the armature coil will cause flashing at the commutator. Two adjacent bars will show severe burning and a resulting overheated armature. If coils or commutator bars are shorted, the short may cause the insulation to be destroyed. This may result in the burning of the armature coils, the banding, or the commutator bars.

Grounds in the armature circuit may be found by using a megohmmeter. Connect one lead to the frame of the generator and the other lead to a commutator bar. If the armature is grounded, the megohmmeter will show less than one megohm.

Bearing Lubrication

The grease that is used in the bearings of the generator loses the ability to lubricate the bearings over time and use. The effective life of the lubricant depends on the following items:

• The type of lubricant that is used

• The size of the bearing

• The operating speed of the bearing

• The operating conditions

Use 2S-3230 Caterpillar Special Grease (SPG) . This is an NLGI No. 2 Grade that has thicker Polyurea. There is no molybdenum disulfide in this grease. The temperature range is −29 °C (−20.2 °F) to 177 °C (350.6 °F). Use NLGI 1 or 0 Grade for extremely low temperatures.

Note: Keep hands, tools and all other equipment clear of the rotating machinery.

Table 35

Generator Size	Recommended Interval For Bearing Lubrication
20 kW and below	Every 2 years
above 20 kW	Every year

1. Clean the grease fitting before you apply the grease.

2. Remove the outlet plug for the grease.

3. Apply grease through the fitting until the grease appears at the hole in the shaft or the purge outlet.

4. Run the generator for 10 minutes.

5. Clean any excess grease from the area of the outlet plug and reinstall the plug.

Brush Check

Note: Do not change grades or the number of brushes per pole. Changing the grades or changing the number of brushes per pole may void the warranty. This may also cause conditions that are unsafe.

Brush life will vary due to loads on the generator and the environment. The leads of the brush should be checked for a secure connection to the stud of the support for the brush. Brushes should be replaced when the brush is half the length of a new brush.

Procedure For Seating The Brushes

1. Wrap a strip of coarse sandpaper (#60) around the commutator and under the brush holder. The rough side of the sandpaper must be facing outward. Do not use a sandpaper that contains metal oxide. Do not use emery cloth that contains electrically conductive materials.

2. Slide the new brush into the holder and snap the spring clip in place.

3. Rotate the armature slowly in the direction of normal rotation.

4. Remove the brush and inspect the face of the brush. The brush should be seated over 90% of the area of the face. The brush should be seated completely from the leading edge to the trailing edge.

   Brushes should move freely in the brush holders. If brushes stick, the cause is usually due to build up of dirt and oil. Brushes should be inspected regularly. Check for sufficient brush length. The brush should press firmly against the commutator. Brush springs should have equal tension. Only brushes of the same size, the same grade and the same shape as the brushes that were originally supplied should be used.

   Brush holders are aligned with a mark before the generator leaves the factory. After the brush holder is replaced, realign the holder to the mark from the factory.

   When the commutator has been turned, the brush holder assembly must be adjusted. When the commutator has been replaced with a new commutator, the brush holder assembly must be adjusted. Maintain a 1.5748 mm (0.062 inch) clearance between the bottom of the brush holder and the commutator. The assembly for the brush holder is designed with a nut/bolt guide assembly. This assembly makes positioning the brush box easier.

   During regular inspections, maintain tight electrical connections and properly insulated electrical connections.

Brush Life

One of the following factors may reduce the life of a brush:

• Overloading

• Excessive generator speed

• Light electrical loads

Brush Chatter or Bouncing

Chatter or bouncing of the brushes can be caused by a vibration from an external source. The vibration source may be a bad coupling or loose mounting hardware.

Brush Sparking

Sparking of the brushes can be caused by mechanical conditions or electrical conditions. Mechanical causes include flat spots on the commutator or external vibration. Electrical causes can be shorted wires or a faulty magnet.

Field Coil Check

Disconnect "F1" and "F4" for the shunt field from the controller for the magnet. Use an ohmmeter in order to check the resistance of the shunt field. Compare the results to data that is on the nameplate. Attach one lead of a megohmmeter to "F1" and the other lead to the frame of the generator. The reading should be over one megohm.

Generator Drive Coupling Check

Remove the plastic inspection cover on the adapter between the hydraulic generator motor and the generator. Examine both halves of the coupling for looseness or unusual wear. Examine the insert for the coupling for looseness or unusual wear.

Walk-Around Inspection

Cleanliness

The inside and the outside of the generator should be kept free of dirt, oil, grease, water, and other substances. If the vent passages that are located on the generator are clogged, the generator may overheat and premature failure can occur.

Connections

Verify that all of the connections are tight. Inspect all the hoses, fittings and components of the hydraulic drive system for leakage.

Vibration

The bearings, the brushes, and the commutator of the generator can be damaged by excessive vibration or mounting hardware that is loose.

Noise

Listen for unusual noise or excessive noise in the bearing area. Check for loose parts on the generator such as through bolts and mounting hardware.

Systems Operation

Generator Set Control

Illustration 56	g01078426
Typical 25 kW Application (1) 234-5084 Hose Assembly (Return) (2) Main pump (3) Hydraulic gear pump (generator) (4) 234-5083 Hose Assembly (Pressure) (5) 234-5082 Hose Assembly (Suction) (6) 234-5085 Hose Assembly (Case Drain)

Illustration 57	g01078427
Typical 25 kW Application (1) 234-5084 Hose Assembly (Return) (2) Main pump (3) Hydraulic gear pump (generator) (4) 234-5083 Hose Assembly (Pressure) (5) 234-5082 Hose Assembly (Suction) (6) 234-5085 Hose Assembly (Case Drain)

Note: Do not start the generator with the engine above low idle speed. If the generator is started above idle speed, damage to the drive coupling can result.

The generator is designed to convert mechanical energy into direct current electrical energy.

The generator must be operated at the rated speed in order to develop the full rated voltage and power. For optimum performance, the speed must be maintained within a ± 50 RPM range.

The generator is a compound field wound unit. The generator is self-regulated between zero and full load. The generated voltage is 230 volts at a constant speed of 1800 RPM.

The generator is designed with an extra thermal capacity. The extra thermal capacity avoids overheating from the use of the magnet. The generator is mechanically mounted in order to resist shock and vibration from the machine.

Hydraulic gear pump (3) takes suction from the hydraulic oil tank of the machine. The hydraulic oil passes through suction hose (5) to hydraulic gear pump (3). The hydraulic gear pump provides a constant flow of hydraulic oil to the generator circuit.

Hydraulic oil from hydraulic gear pump (3) passes through pressure hose (4) into the hydraulic generator manifold. The hydraulic oil is sent through a compensator valve which is used to control the operation of the generator. When the compensator valve is energized, hydraulic oil is allowed to flow to the hydraulic motor. After the hydraulic oil passes through the hydraulic motor or when the compensator valve is de-energized, the hydraulic oil is routed to the hydraulic oil tank. The hydraulic oil bypasses the hydraulic motor and passes through return hose (1). The hydraulic oil then flows to the connection to the return line to the hydraulic oil tank.

Illustration 58	g00332116
(1) Grapple/magnet switch.

When the grapple/magnet switch is turned to the magnet ON position, the compensator valve is energized. The grapple/magnet switch is located on the right console. When the compensator valve is energized, the spool in the valve shifts. When the valve shifts, hydraulic oil is allowed to flow through the hydraulic generator manifold to the hydraulic motor. The hydraulic generator manifold regulates the hydraulic flow to the hydraulic motor. The regulation of the hydraulic oil maintains a constant motor speed. The hydraulic oil is used to operate the hydraulic motor. Hydraulic oil from the hydraulic motor returns to the hydraulic oil tank through hose (1) .

The hydraulic motor is used as the mechanical power source for the generator. The generator is coupled to the hydraulic motor. The generator produces the required voltage and power for the magnet.

The hydraulic generator controller is equipped with a disconnect switch. The disconnect switch controls the entire electrical system of the hydraulic generator control circuit. A control for the shunt field circuit is included in the hydraulic generator controller. The control for the field discharge circuit is included in order to dissipate the inductive energy of the magnet when the magnet is not active.

Illustration 59	g00332555
This is a view of the indicator box.

A monitor is installed in the cab of the machine in order to indicate the status of the circuit for the magnet. The monitor also alerts the operator if any problems occur in the system.

Compensator Valve

Illustration 60	g00381452
(1) hydraulic generator manifold (2) Return hose (outlet) (3) Pressure hose (inlet) (4) "G1" port (5) "G2" port (6) "A" port to generator (7) "B" return line to hydraulic oil tank (8) Two-way valve (9) Compensator valve (10) Relief valve (11) "LS" port (12) Adjustable flow control orifice (13) Adjustable orifice (14) Soft start valve (15) Anticavitation check valve (16) Orifice

Illustration 61	g00789556
(1) Hydraulic generator manifold (2) Return hose (3) Pressure hose

Compensator valve (9) is located inside hydraulic generator manifold (1). Refer to Illustration 60. Compensator valve (9) maintains constant generator speed even when there is some fluctuation in engine speed. hydraulic generator manifold (1) is located at the inlet to the hydraulic motor. The hydraulic generator manifold controls the operation of the generator by controlling hydraulic oil flow.

hydraulic generator manifold (1) includes both two-way valve (8) and compensator valve (9). Two-way valve (8) directs the hydraulic oil to the compensator valve or to the hydraulic oil tank. When the generator is not active, the two-way valve directs the hydraulic oil to the hydraulic oil tank. Hydraulic oil travels from the hydraulic generator manifold to the hydraulic oil tank through hose (2). When the two-way valve directs oil to compensator valve (9), the compensator valve controls the amount of hydraulic oil that is sent to the hydraulic motor. Excess hydraulic oil is sent to the hydraulic motor that is driving the generator in order to keep the generator operating at a constant speed. The excess hydraulic oil from the hydraulic motor that is driving the generator is sent to the hydraulic oil tank.

The hydraulic generator manifold includes relief valve (10). The relief valve prevents the buildup of the hydraulic pressure. The buildup of hydraulic pressure could damage the hydraulic motor that is driving the generator. The relief valve is an adjustable relief valve in order to change the relief setting on the system.

Components of the Hydraulic Generator Manifold

(4) "G1" - This is the gauge port that is used to check the inlet pressure of the generator hydraulic manifold. This port is also used to find the system pressure. The system pressure is the pressure which is required to operate a certain work load. The system pressure is the pressure that is required to turn the generator at a given rpm under a rated load.

(5) "G2" - This is the test port that is used to check the pressure that returns to the hydraulic oil tank. The pressure that returns to the hydraulic oil tank is the back pressure.

(8) "SV02" - This solenoid valve is the valve that turns the generator ON or OFF. This solenoid valve is wired to the grapple/magnet switch in the cab. The grapple/magnet switch sends power to the solenoid valve when the switch is in the GENERATOR position.

(9) "FCS01" - This is the compensator that is built into the hydraulic generator manifold. This valve needs no adjustments.

(10) "RV01" - This is the relief valve that sets the system at the rated load pressure. When you set the relief valve find the system pressure. Turn the relief valve half of a turn in the clockwise direction. In order to find the system pressure, refer to "G1". When the stem of the relief valve is adjusted in the clockwise direction, the system pressure will increase. When the stem of the relief valve is adjusted in the counterclockwise direction, the system pressure will decrease.

(11) "LS" - This is a gauge port that is used to check the differential pressure. The pressure at this port does not need to be checked unless there is a problem with the operation of the system.

(12) "FCNV01" - This adjusting stem is used to set the speed of the generator. To increase the speed, the stem is turned in the counterclockwise direction. To decrease the speed, the stem is turned in the clockwise direction.

(13) "NV02" - This adjusting stem is used to set the bounce when the generator is operating at the correct rpm. The proper rpm is between 1750 and 1800 rpm. The adjustment will be very slight. After the bounce has been removed, check the rpm of the generator again.

(14) "SV01" - This is the soft start solenoid valve. The soft start solenoid valve and the drop switch are connected to the same terminal in the controller. The drop switch is the trigger switch on the left work tool control lever.

(15) "CV01" - This is the anticavitation check valve that is built into the hydraulic generator manifold. This valve needs no adjustments.

(16) "OR02" - This is an orifice that needs no adjustments.

Troubleshooting the Generator

Magnet Pickup

Show/hide table

System operates at 230 Volts DC. Extreme caution should be taken while measuring the voltage.

Note: Voltage and current must be measured while the engine is operating at full throttle. Stop the engine and disconnect all of the power in order to check the resistance through the circuit for the magnet.

Symptom: - The magnet does not lift any scrap.

Case 1: - The "Magnet On" indicator is on.

1. Open the door to the controller of the magnet. Move the generator disconnect switch to the ON position. Depress the lift switch that is located on the right work tool control lever. You will need another person in order to depress the button.

2. Use a digital multimeter in order to measure the voltage between blocks "PDB151 (+)" and "PDB152(-)". Depress the drop switch and allow the magnet control to cycle through the drop cycle. The duration of the drop cycle is approximately 5 to 7 seconds. The duration of the drop cycle can be shorter if "C181" contactor coil becomes energized. Set the digital multimeter to the scale for 0 to 500 DC voltage. The voltage should be at least 230 volts. If the voltage is correct, proceed to Step 3. If the voltage is not correct, proceed to Step 4.

3. Move the generator disconnect switch to the OFF position. Disconnect the leads to the magnet at "PDB151" and "PDB152". Use the digital multimeter in order to measure the resistance across the disconnected leads. Set the digital multimeter on the lowest scale for ohms. The measured resistance should correspond to the specifications that are attached to the magnet. If the resistance is not within the range, check the magnet and the cable to the magnet. Reconnect the leads to "PDB151" and "PDB152".

4. Use the digital multimeter in order to check for a positive field voltage during the lift cycle. Check the field voltage at terminals "101D (+)" and "102D (−)". The voltage should read 24 to 28 VDC for the first 3 seconds after the lift switch is pressed. The voltage should then drop to approximately one half of the value for the remainder of the lift cycle. If the voltage is correct, proceed to Step 5. If there is no voltage at "101D" and "102D", then check "CR169" relay, "R101" resistor, "SSR170" and "SSR171". Replace any components that are faulty.

5. Check the speed of the generator. The speed of the generator should be 1800 ± 100 RPM. If the speed is not correct, refer to the hydraulic system. Check the soft start valve. Within 3 seconds after the system is started, the red indicator light on "TR106" should light. The coil for the soft start solenoid should de-energize. If the soft start valve is energized, check relay "TR106". If the relay is faulty, replace the relay. If the speed is correct, turn the grapple/magnet switch to the Magnet OFF position in order to stop the generator. Turn the key start switch to the OFF position in order to stop the engine. Check the brushes of the generator. The brushes should be in good contact with the commutator.

Case 2: - The "Magnet On" indicator is off.

1. Open the door to the hydraulic generator controller. Move the generator disconnect switch to the ON position. Depress the lift switch on the right work tool control lever. You will need another person in order to depress the button. Use a digital multimeter in order to check for 25 to 28 VDC at terminal "101B (-)" and "102C (+)". No voltage at terminal "101B (-)" and "102C (+)" requires the following steps. Measure the voltage at the disconnect switch "DISC101" and the fuses "FU101A" and "FU101B".

2. The temperature switches are preset for "TS107A" at −1.1°C (30°F). The temperature switches are preset for "TS107B" at 21.1°C (70°F). If "CR107" does not energize, place a jumper across the terminals on "TS107A". "CR107" should then energize the latch mechanism. If "CR107" fails to energize the latch mechanism, replace "CR107". If "CR107" energizes the latch mechanism, replace "TS107A". If the ambient temperature is below 4.4°C (40°F), then the "TS107B" contacts should be closed. The strip heater in the bottom of the Programmable Logic Controller will energize. Check for voltage from "107B" to "102C". If the voltage is 20 to 28 VDC, the "TS107B" is correct. If no heat is detected from the strip heater ("HTR107"), replace the heater.

3. Check fuse "FU108".

   Note: Only use the type and the size of fuse that is specified in the parts book. The use of any other type or size of fuse can result in permanent damage to the Programmable Logic Controller.

4. Check the voltage from "110 (+)" to "110C (−)". The voltage reading should be in a range between 1 and 2 VDC. This reading should be lower than the voltage reading at the bottom of the disconnect switch. The voltage should be in a range between 22 and 27.5 VDC.

5. Check the Programmable Logic Controller. "POWER" and "RUN" indicators should be on.

   1. If the "POWER" indicator is off, check for 22 to 27.5 VDC at the "DC IN+24" and "COM−24" terminals that are located on the Programmable Logic Controller. If the voltage is present, replace the Programmable Logic Controller.

   2. If the "POWER" indicator is on and the "RUN" indicator is off replace the Programmable Logic Controller.

   3. If "FAULT" indicator is on, replace the Programmable Logic Controller.

6. Check the "LIFT" input. When the lift switch is depressed, there should be 22 VDC at terminal "117 (+)" and "102C (−)". The Programmable Logic Controller "input I/4" should be energized. If the voltage is not 22 VDC, check the wires to the switch button that is located on the joystick. Check the fuse for the joystick control.

Symptom: - The scrap does not drop.

The following table provides approximate settings for the select switch and approximate settings for the range switch. The range switch is located on the lower right exterior of the Programmable Logic Controller.

Table 36

Initial Settings
Size of the Magnet	Setting of the Range Switch	Rotary Dial Setting
Up to 1219 mm (48 inch)	OFF	1-3
1245 to 1448 mm (49 to 57 inch)	OFF	3-5
1473 to 1676 mm (58 to 66 inch)	OFF	5-7
1473 to 1676 mm (58 to 66 inch)	OFF	7-9
1676 to 1829 mm (66 to 72 inch)	OFF/ON	1-3
1676 to 1829 mm (66 to 72 inch)	OFF/ON	3-5

Note: The initial settings are only suggestions. The actual settings may vary depending on the manufacturer of the magnet. The type of magnet as well as the material type and consistency will also change the setting. Generally for the larger magnets, the dial setting is higher. Usually, the range switch should be in the OFF position when the magnet measures 1676 mm (66 inch) or less. This switch should only be turned to the ON position when a clean drop cannot be achieved at any dial setting in the OFF position. Normally, the ON setting will be necessary only when the magnet measures 1829 mm (72 inch) or more.

1. Check the "DROP" input. When the drop switch is depressed, there should be 25 to 28 VDC at terminal "118 (+)" and "102C (−)". The input "I/5" for the Programmable Logic Controller should be energized. If the voltage is not correct, check the cables to the joystick.

Symptom: - The scrap does not drop cleanly.

1. Adjust the drop time by rotating the select switch. The select switch is located on the monitor panel.

2. During the drop time, check for negative field voltage at terminal "102D (−)" and "101D (+)". If there is no negative field voltage, check "SSR172" and "SSR173". "SSR172" and "SSR173" should be energized during the drop time. If there is a signal from output "O/5" of the Programmable Logic Controller but no negative voltage, replace "SSR172" and "SSR173".

Descriptions for the Fault Indicator

Volts Fault Indicator

The voltage for the magnet can cause an "Over Voltage" or "Under Voltage" indication.

Measure the voltage of the magnet at terminals "PDB151" and "PDB152" during lifting. Measure the voltage at least three seconds after the lift switch is depressed. The voltage should be 200 to 250 VDC.

If the voltage of the magnet is out of the range, proceed with the following steps:

1. Check the field voltage at terminals "101C" and "102D". The voltage should be 25 to 28 VDC.

   1. If the field voltage is out of the range, check the voltage regulator and check the charging system of the machine.

   2. If the field voltage is normal, check the generator speed. The speed of the generator should be 1800 ± 100 RPM%. If the generator is not turning at the correct speed, refer to the hydraulic section for instructions.

2. Check the "Voltage Boost Relay (CR169)". The "Voltage Boost Relay (CR169)" should open within three seconds after the lift switch is depressed. There should be a voltage drop across "R101". Measure the voltage drop between "101C" and "101D".

If the voltage is within the range, proceed with the following steps:

1. Check the setting on "VBM151". The setting should be the following conditions:
   • "UNDER=200"

   • "OVER=260"

2. If the settings are correct, check "CR168". "CR168" should be energized for 1.5 seconds. "CR168" should energize in approximately 9 seconds after the lift button is depressed. During the 1.5 seconds, the voltage at "terminal 2" and "terminal 7" of the voltage band monitor should be within the specified range. If the voltage is not within the specified range, the lighted LED on "VBM151" should illuminate. The output of "VBM151" should energize input "I/8" of the Programmable Logic Controller.

Show/hide table

System operates at 230 Volts DC. Extreme caution should be taken while measuring the voltage.

Over 75% DC Fault Indicator

The "Over 75% DC" fault occurs if the magnet is energized more than 7.5 minutes in a 10 minute period. Once the fault occurs a minimum of 10 minutes must pass in order to clear the fault.

Generator Hot Indicator

The temperature switch that is in the generator is open due to excessive generator heat. Leave the generator running under no load until the generator cools down. No load means that you do not use the magnet. The "GEN HOT" indicator will remain on until the generator temperature drops to an acceptable level. Turn the generator disconnect switch to the OFF position. Turn the generator disconnect switch back to the ON position in order to reset the hydraulic generator controller.

Ground Fault Indicator

The magnet, the generator or the cable is in a grounded condition. The indicator will become brighter as the fault increases.

Show/hide table

Prior to repairing cable breaks or removing the magnet, the following steps must be taken:

1. De-energize the magnet. Depress the drop switch.

2. Place the machine engine in low idle.

3. Move the grapple/magnet switch to the Magnet OFF position.

4. Move the generator disconnect switch to the OFF position.

Return To Magnet Control

1. Move the generator disconnect switch to the ON position.

2. Move the grapple/magnet switch to the Magnet ON position.

3. Move the engine speed dial to position 10. The engine is now in high idle.

4. Resume operation.

Testing and Adjusting

General Testing and Adjusting Information

Show/hide table

Hydraulic oil pressure can remain in the hydraulic systems after the engine and pump have been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic systems. To prevent possible injury, refer to the section, Testing and Adjusting, "Hydraulic System Pressure - Release" before any fitting, hose or component is loosened, tightened, removed or adjusted. When possible, the work tool must always be lowered to the ground before service is started. When it is necessary for the boom to be in the raised position while tests or adjustments are done, be sure that the boom, stick and work tool have correct support. The swing lock (if equipped) must be engaged before service is started. Always move the machine to a location away from the travel of other machines. Be sure that other personnel are not near the machine when the engine is running and tests or adjustments are being made.

The correct oil temperature, the correct flow and the correct pressure are necessary for correct operation. Pump output is a function of the engine speed. Oil pressure is caused by resistance to the flow of oil.

Visual Inspection

A visual inspection of the system is the first step in troubleshooting a problem. Make the inspection with the engine in the off position and the attachment lowered to the ground.

1. Check the level of the oil in the hydraulic tank. Slowly loosen the vent plug for the hydraulic tank. Release the pressure in the tank before the filler cap is removed.

2. Remove the filter element. Check the filter for foreign material that would give an indication of damage to a component.

3. Inspect all lines and connections for damage or leaks.

4. Inspect the control linkage for bent lines, broken components or damaged components.

Check During Operation

The check during operation can be used to find leakage in the system. The check can also be used in order to find a valve, a pump, a motor or a cylinder that is not operating correctly. The speed of the rod movement or the torque on a motor can be used to check the condition of the cylinders, motors, and pumps.

Testing and Adjusting the Magnet

In order to determine the condition of the magnet, the resistance must be measured. Measure the resistance of the coil. Measure the resistance of the insulation to ground. Compare the resistance readings with the original readings from the manufacturer.

• The coil resistance should be within 5 percent of the original value when the magnet is at ambient temperature. The ambient temperature is considered to be 25°C (77°F).

• When the magnet is hot, the coil resistance can increase to 143 percent of the ambient value.

• The resistance to ground on a magnet at ambient temperature should be over one megohm.

• When the magnet is hot, the ground resistance can drop to 0.05 megohm. The magnet is considered grounded if the value is below 0.05 megohm. The magnet should be repaired.

In order to check the resistance of the magnet, use a resistance bridge, or a meter with a 0.10 ohm accuracy. Also, use a 500 volt ground megohmmeter.

1. Turn the grapple/magnet switch to the Magnet OFF position in order to stop the generator. Move the generator disconnect switch to the OFF position. Lock the switch in the OFF position.

2. Set the magnet on the ground. Disconnect the leads that come from the front of the machine.

3. Connect the resistance bridge to the 2 leads that are attached to the magnet. An ohmmeter can be used in place of the resistance bridge. Measure the resistance. Compare the reading to the original readings from the manufacturer. If the measurements are within tolerance proceed to Step 5. If the readings are not within tolerance proceed to Step 4.

4. Disconnect the leads from the terminals of the magnet. Take a reading directly from the terminals of the magnet. If the readings are now within tolerance, replace the leads of the magnet. If the readings are not within tolerance consult the manufacturer of the magnet for instructions.

5. Clean the exterior of the magnet. Attach the 2 leads from the megohmmeter to the case of the magnet. Take a reading. The resistance reading should be zero. If the reading is not zero place the leads in a different place and measure the resistance again. Once you have obtained a zero reading on the megohmmeter, remove one of the leads and attach the lead to the terminal of the magnet. Make sure that the other lead is not touching the magnet or any metal. Take a resistance reading. If the reading is above 0.5 megohm the magnet is within tolerance. If the reading is below 0.5 megohm consult the manufacturer of the magnet for instructions.

Testing and Adjusting the Generator

Show/hide table

Before making any adjustments to the generator the engine must be shut off and the main disconnect switch on the controller must be in the off position. Personal injury can occur. Close all controller panel doors before the generator is started. Personal injury can occur. Never handle the leads to the magnet unless the generator is stopped and the main disconnect switch on the controller is in the off position. Personal injury can occur.

Show/hide table

NOTICE
Do not start the generator with the engine running above low idle speed. Failure to do so can cause damage to the generator drive coupling.

Illustration 62	g00332116
(1) Grapple/Magnet switch

1. Turn the key start switch to the OFF position in order to stop the engine.

   1. Place grapple/magnet switch (1) in the Magnet OFF position. The grapple/magnet switch is located on the right console.

   2. Place the generator disconnect switch in the OFF position. The generator disconnect switch is on the hydraulic generator controller.

   3. Remove the cover to the drive shaft of the generator.

   4. Attach a reflective tape to the drive shaft of the generator.

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

   1. With the engine at low idle, place the generator disconnect switch in the ON position.

   2. Place grapple/magnet switch (1) in the Magnet ON position. The grapple/magnet switch is located on the right console.

   3. Move the engine speed dial to position 10. The engine is now in high idle.

      Note: The AEC is disabled when the grapple/magnet switch on the right console is in the Magnet ON position. The generator should now be running.

Show/hide table



Illustration 63	g01030006
(3) Adjustment screw for the compensator valve

Show/hide table



Illustration 64	g00332119
(4) Power resistor

3. With the engine at high idle, adjust the speed of the generator to 1800 RPM.

   1. Adjust the speed of the generator by turning the screw on the compensator valve (3). The adjustment screw for the compensator valve (3) is located on the hydraulic generator manifold. Turning the adjustment screw clockwise decreases the generator speed. Turning the adjustment screw counterclockwise increases the generator speed.

4. Adjust the voltage to 230 ± 10 volts.

   1. Operate the generator with the engine at high idle. Use a digital multimeter in order to observe the voltage.

   2. Stop the generator and the engine. Adjust power resistor (4) for the hydraulic generator controller. Downward movement of the contact lead decreases the voltage. Upward movement of the contact lead increases the voltage.

   3. Close all of the access panels. Start the engine and operate the generator. Check the voltage. If the voltage is not correct, repeat the procedure to adjust the voltage. Adjust the voltage until the correct voltage is obtained.

Show/hide table



Illustration 65	g00332120
(5) Disconnect switch for the hydraulic generator controller

5. Stop the generator and turn the key start switch to the OFF position in order to stop the engine.

   1. Move generator disconnect switch (5) on the hydraulic generator controller to the OFF position.

   2. Install the magnet and connect the main leads to the magnet.

   3. Move the generator disconnect switch to the ON position.

   4. Start the engine and place the engine in low idle. With the engine at low idle, start the generator and move the engine speed dial to position 10. The engine is now in high idle.

Show/hide table



Illustration 66	g00332122
(6) Lift/Drop switch

6. Move the right trigger switch (6) to the lift position. The magnet should now lift material.