320B, 320C, 322B, 322C, 325, 325B, 325C, 325D, 330, 330B, 330C, 330D, 345B, 345B Series II, 345C, 350, 350L, 365B, 365BL, 365BL Series II, 365C, 375L, 385C, 5080, M318, M320, M325B, M325C, M325D, W330B and W345B Series II Excavators Magnet Controller Caterpillar

System Operation Description:

The following conditions are required for the operation of the magnet:

Illustration 1	g00786017
Grapple/Magnet Switch on all models except 325C, 330C and 345C MH

Illustration 2	g01000512
Grapple/Magnet Switch on 325C and 330C

Illustration 3	g01151752
The Grapple/Magnet Switch on 345C MH

• The boom priority mode switch must be ON. The boom priority mode switch is located on the top left side of the monitoring panel in the cab.

• The power mode switch must be ON. The power mode switch is located on the top right side of the monitoring panel in the cab.

• The engine speed dial must be set to position 10. Verify that the engine is running at high idle speed.

• The grapple/magnet switch must be in the MAGNET position. When the grapple/magnet switch is turned to MAGNET position, the solenoid valve (SV02) is energized.

• The disconnect switch must be in the ON position.

• The hydraulic lockout lever must be in the UNLOCKED position.

Note: The magnet should be energized only when the engine speed is at the proper rpm. When the generator is at a lower speed and a load is placed on the generator, the output voltage is reduced. The output in amperes is reduced. The cooling ability of the generator is significantly reduced. This can lead to failure of the generator.

Note: The generator will not rotate until the grapple/magnet switch is in the MAGNET position. The Automatic Engine Control (AEC) will be bypassed when the grapple/magnet switch is in the MAGNET position. The engine is not allowed to return to idle which would drop a load. The generator is also protected.

Note: When the hydraulic lockout lever is in the locked position, the signal for the lift function and drop function do not reach the controller.

Test Step 1. OBSERVE THE INDICATOR.

1. Press the lift switch on the RH joystick.

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Illustration 4	g00274430
Controller for the Magnet on all models except 325C and 330C 345C MH

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Illustration 5	g01000045
Controller for the Magnet on 325C and 330C

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Illustration 6	g01151143
Controller for the Magnet for 345C MH

2. Look at the monitor for the magnet.

Expected Result:

The "Magnet On" indicator is ON.

Results:

• YES - The "Magnet On" indicator is ON. Proceed to Test Step 2.

• NO - The "Magnet On" indicator is OFF. Proceed to Test Step 5.

Test Step 2. MEASURE THE VOLTAGE.

1. Press the drop switch on the LH joystick.

Note: Never turn OFF the ignition key and never open the disconnect switch when the system is in the lift mode in order to prevent possible damage to the controller.

2. Turn the disconnect switch ("DISC 101") to the OFF (open) position.

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Illustration 7	g00717550
Technique for opening the control panel

3. Open the Control panel by squeezing the tab on the disconnect switch between the thumb and the finger. See illustration 7.

4. When the panel door is open, turn the disconnect switch ("DISC 101") to the closed position. The machine

5. Start the machine.

6. The generator output voltage should be between 240 and 270 DCV for the first 3 seconds after pressing the lift switch. After 3 seconds, the voltage should measure 230 DCV. Press the lift switch that is on the RH joystick. You will need another person to press the switch.

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Illustration 8	g00780192
(1) Terminal "PDB151" (2) Terminal "PDB152" (3) Main Fuse "FU151"

7. Set the digital multimeter to measure DCV. Connect the positive lead of the digital multimeter to the terminal on the top side of the main fuse (3) and the negative lead on terminal "PDB152" (2) .

8. Record the values that were measured in the previous step. The value will be negative or the value will be positive.

9. Connect the positive lead of the digital multimeter on terminal "PDB151" (1) and the negative lead on terminal "PDB152" (2) .

10. Press the drop switch that is on the LH joystick. You will need another person to press the switch. The generator output voltage will rapidly decrease from 230 DCV. The voltage will reach -240 to -270 DCV in the negative direction. The voltage will rapidly return to approximately zero DCV after the drop cycle has ended. The length of time for the drop cycle will vary with the size of the magnet and the dial setting on the monitor.

Expected Result:

The voltage should measure at least 230 DCV during the lift cycle.

Results:

• YES - The voltage is at least 230 DCV. Proceed to Test Step 3.

• NO - The voltage is not at least 230 DCV. Proceed to Test Step 6.

Test Step 3. CHECK THE FUSE.

1. Turn the key start switch to the OFF position.

2. Turn the disconnect switch for the generator ("DISC 101") to the OFF position.

3. Ensure that the generator is not rotating.

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Illustration 9	g00780192
(1) Terminal "PDB151" (2) Terminal "PDB152" (3) Main Fuse "FU151"

4. Measure the resistance of the fuse for main power (3) .

Expected Result:

The resistance measurement is less than 1 ohm.

Results:

• YES - The resistance measurement is less than 1 ohm. The fuse is good. Proceed to Test Step 4.

• NO - The resistance measurement is not less than 1 ohm.

  Repair: The fuse has failed. Replace the fuse for main power (1) . See table 1 in the Systems Operation, "General Information" section for the correct fuse size. Inspect the generator for damage. Verify that the new fuse corrects the problem.

  STOP

Test Step 4. MEASURE THE RESISTANCE.

1. The key start switch and the disconnect switch should still be in the OFF position.

2. Ensure that the generator is not rotating.

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Illustration 10	g00780192
(1) Terminal "PDB151" (2) Terminal "PDB152" (3) Main Fuse

3. Disconnect the leads to the magnet at "PDB151" (1) and "PDB152" (2) .

4. Use the digital multimeter in order to measure the resistance across the disconnected leads. Set the digital multimeter on the lowest scale for measuring resistance.

Expected Result:

The resistance measurement will be above the value that is on the nameplate of the magnet or the resistance measurement will be below the value that is on the nameplate of the magnet.

Note: The resistance of a magnet that is at operating temperature is expected to be 125 percent to 135 percent higher than the rating on the nameplate.

Results:

• ABOVE - The resistance measurement is above the value that is on the nameplate of the magnet.

  Repair: There is an open circuit. Inspect the magnet and inspect the cables to the magnet for damage. Replace the cables or replace the magnet.

  STOP

• BELOW - The resistance measurement is below the value that is on the nameplate of the magnet.

  Repair: The circuit is shorted. Inspect the magnet and inspect the cables to the magnet for damage. If the magnet or the cables are shorted, replace the magnet or the cables. When the magnet circuit is shorted, the fuse "FU151" for the main power (3) will open in order to protect the generator. It is possible to have a short that is not severe enough to blow the main fuse. If the short exists for a long time, the generator may be damaged. Inspect the generator for damage when any short is found. Inspect the generator for damage when any blown fuse is found.

  STOP

Test Step 5. CHECK THE STATUS OF THE OUTPUT.

1. Press the drop switch on the LH joystick in order to take the machine out of lift mode.

Note: Never turn OFF the ignition key and never open the disconnect switch when the system is in the lift mode in order to prevent possible damage to the controller.

2. Turn the disconnect switch ("DISC 101") to the OFF position.

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Illustration 11	g00717550
Technique for opening the control panel

3. Open the Control panel by squeezing the tab on the disconnect switch between the thumb and the finger. See illustration 11.

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Illustration 12	g00780336
Inside of the Control Panel for the Magnet (4) Screw.

4. Remove the cover for the Programmable Logic Controller (PLC) by removing the four screws (4) .

5. Turn the disconnect switch ("DISC 101") to the ON position.

   Note: The key start switch must be in the ON position. The lockout lever must be in the UNLOCKED position.

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Illustration 13	g00718451
Location of Output 4 on the PLC

6. While the operator presses the lift switch on the RH lever, observe the LED indicator for output 4.

Expected Result:

The LED indicator for output 4 is ON.

Results:

• YES - The LED indicator for output 4 is ON.

  Repair: The lift function is working. The "Magnet On" indicator on the monitor or the wiring to the monitor has failed. Press the drop switch on the LH joystick. Turn the key start switch to the OFF position. Turn the disconnect switch to the OFF (open) position. Repair the component or replace the component that has failed.

  STOP

• NO - The LED indicator for output 4 is not ON. Proceed to Test Step 16.

Test Step 6. CHECK THE GENERATOR.

Note: The engine must be running at high idle. The magnet/grapple switch must be in the magnet position in order for the generator to spin at the correct rpm. The output voltage of the generator will vary directly with rpm.

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Illustration 14	g00786166
(5) Generator Cover

1. Remove the inspection cover. Observe the coupling between the hydraulic motor and the generator.

Expected Result:

The generator should be turning.

Results:

• YES - The generator is turning. Proceed to Test Step 14.

• NO - The generator is not turning. Proceed to Test Step 7.

Test Step 7. OBSERVE THE INDICATOR.

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Illustration 15	g00780398
(6) Soft Start Solenoid ("SV01") (7) Enable Solenoid ("SV02") (8) Adjustment for priority flow

1. Observe the indicator for Enable Solenoid ("SV02"). The indicator is located on the connector for the solenoid.

Expected Result:

The indicator for the Enable Solenoid ("SV02") is on.

Results:

• YES - The indicator for the Enable Solenoid ("SV02") is ON. A voltage of 24 DCV is present at the solenoid. Proceed to Test Step 8.

• NO - The indicator for the Enable Solenoid ("SV02") is OFF. A voltage of 24 DCV is not present at the solenoid. Proceed to Test Step 10.

Test Step 8. CHECK THE COIL.

1. Hold a small screwdriver very close to the end of the Enable Solenoid ("SV02").

Expected Result:

The solenoid will attract the screwdriver.

Results:

• YES - The screwdriver is attracted by the solenoid. Proceed to Test Step 9.

• NO - The screwdriver is not attracted by the solenoid.

  Repair: The solenoid has failed. Replace the solenoid. Verify that the new solenoid corrects the problem.

  STOP

Test Step 9. CHECK THE HYDRAULIC FLOW.

1. Install a flow meter between the generator pump and the hydraulic manifold. The hydraulic manifold is located at the generator motor. The flow meter must measure flow of 303 L/min (80 US gpm).

2. Operate the machine with the following conditions:
   • The throttle is full.

   • The magnet mode is on.

   • The boom priority is on.

   • The AEC is off.

   • The power mode is U3.

   A magnet must be connected to the generator in order to troubleshoot the hydraulic system. A load test bank may be substituted. Check that the engine RPM is correct by using the monitor for the machine.

Table 1

ITEM	10 KW	15 KW	20 KW	25 KW	33 KW	40 KW	UNIT
Loaded GA1	1440 to 1760	1890 to 2310	2070 to 2530	2520 to 3080	2850 to 3300	3562 to 3937	PSI
Loaded LS	765 to 935	1710 to 2090	1890 to 2310	2340 to 2860	2520 to 3080	3372 to 3728	PSI
Loaded GA2	60 to 150	60 to 150	60 to 150	60 to 150	60 to 150	60 to 150	PSI
Loaded Case Drain	5 to 15	5 to 15	5 to 15	5 to 15	5 to 15	5 to 15	PSI
Flow (Lift Cycle)	24 to 32	39 to 42	39 to 42	39 to 42	39 to 42	46 to 52	GPM
RPM (Lift Cycle)	1750 ± 50	1750 ± 50	1750 ± 50	1750 ± 50	1750 ± 50	1750 ± 50	RPM

Illustration 16	g00786180
(9) Hydraulic Pump

Expected Result:

The hydraulic flow will be verified according to the rating (kW) of the generator. See the table 1.

Note: The pressures that are listed in the table will only be reached when the system is connected to a load bank or a cold magnet. As the magnet warms up, the kW that is required will decrease up to 30 percent. The PSI that is required will decrease up to 30 percent.

Results:

• YES - The hydraulic flow for the generator is correct.

  Repair: Install pressure gauges (0 to 5000 psi) in the following locations on the hydraulic manifold: GA1, GA2 case drain and LS ports. Close the needle valve cartridge (NV02) on the hydraulic manifold. Turn the stem valve clockwise until the valve is fully screwed. This will completely close this needle valve. Initiate the lift cycle and monitor the flow and pressures. The flow may drop one to three gallons per minute in lift mode. The pressure will increase and the pressure will stabilize according to the generator load. Check if the RPM drops below the specified RPM with the increase of pressure. If the drop in RPM is excessive, check the operation of the relief valve (generator drive manifold). Check the setting. The generator motor may have failed internally. The generator couplings may have separated.

  STOP

• NO - The hydraulic flow for the generator is not correct.

  Repair: Inspect the motor drive and inspect the gear pump. Replace any failed components and retest the system.

  STOP

Test Step 10. MEASURE THE VOLTAGE.

Illustration 17	g00786196
Terminal Strip

1. Set the digital multimeter to the scale for DCV.

2. Connect the positive lead of the multimeter to terminal 104A on the terminal strip. Connect the negative lead of the multimeter to 102C. Refer to the Electrical System Schematic, RENR3125.

3. Measure the voltage.

Expected Result:

The voltage should measure 24 DCV.

Results:

• YES - The voltage measures 24 DCV.

  Repair: The wiring between the terminal board and "SV02" has failed. Turn the key start switch to the OFF. Turn the disconnect switch to the OFF position. Replace the wiring. Verify that the new wiring corrects the problem.

  STOP

• NO - The voltage does not measure 24 DCV. Proceed to Test Step 11.

Test Step 11. MEASURE THE VOLTAGE.

1. Set the digital multimeter to the scale for DCV.

2. Connect the positive lead of the multimeter to wire 104B on "FU-B". Connect the negative lead of the multimeter to 102C. Refer to the Electrical System Schematic, RENR3125.

3. Measure the voltage.

Expected Result:

The voltage should measure 24 DCV.

Results:

• YES - The voltage measures 24 DCV.

  Repair: "FU-B" has failed. Turn the disconnect switch to the OFF position. Replace the fuse with a fuse that has the same rating. Remove "TVS-B" from the panel. Measure the resistance of "TVS-B". If the resistance is less than 5 ohms then replace "TVS-B". Resume normal machine operation.

  STOP

• NO - The voltage does not measure 24 DCV. Proceed to Test Step 12.

Test Step 12. MEASURE THE VOLTAGE.

1. Set the digital multimeter to the scale for DCV.

2. Connect the positive lead of the multimeter to terminal 104 on the terminal strip. Connect the negative lead of the multimeter to 102C. Refer to the Electrical System Schematic, RENR3125.

3. Measure the voltage.

Expected Result:

The voltage should measure 24 DCV.

Results:

• YES - The voltage measures 24 DCV.

  Repair: Pole "N" on the disconnect switch has failed or the wiring from the disconnect switch in the terminal board is open. Turn the starter key switch to the OFF position. Turn the disconnect switch to the OFF position. Replace the pole or repair the wiring.

  STOP

• NO - The voltage does not measure 24 DCV. Proceed to Test Step 13.

Test Step 13. CHECK FOR AN OPEN CIRCUIT.

1. Select the DCV range on the digital multimeter.

2. Connect the negative lead of the digital multimeter to ground. Connect the positive lead to wire 180-GN on the fuse for the "AUX" circuit.

3. Measure the voltage.

Expected Result:

The voltage measures approximately 24 DCV.

Results:

• YES - The voltage measures approximately 24 DCV. The fuse for the "AUX" circuit is good. The magnet/grapple switch may have failed. The harness to the switch may have failed. The switch for the lockout lever may have failed.

  Repair: Press the drop switch. Turn the key start switch to the OFF position. Turn the disconnect switch to the OFF position. Replace the component that has failed. Verify that the new component corrects the problem.

  STOP

• NO - The voltage does not measure Approximately 24 DCV.

  Repair: The fuse for the "AUX" circuit is open. Press the drop switch. Turn the key start switch to the OFF position. Turn the disconnect switch to the OFF position. Replace the fuse with a fuse that has the same rating and type. Verify that the new fuse corrects the problem.

  STOP

Test Step 14. CHECK THE SPEED OF THE GENERATOR.

Illustration 18	g00786166
(5) Generator cover

1. Press the drop switch on the LH joystick.

Note: Never turn OFF the ignition key and never open the disconnect switch when the system is in the lift mode in order to prevent possible damage to the controller.

2. Turn the key start switch to the OFF position.

3. Ensure that the generator is not rotating.

4. Place a small strip of the 1U-6605 Reflective Tape on the coupling of the hydraulic motor and the generator. If tape is already present, do not apply additional tape.

5. Restart the engine and run the engine at high idle.

6. Measure the RPM of the reflective tape with the 1U-6602 Photo-Tachometer .

Expected Result:

The speed should measure 1800 ± 50 rpm.

Results:

• YES - The speed measures 1800 ± 50 rpm, but the output voltage is not correct. Proceed to Test Step 40.

• NO - The speed does not measure 1800 ± 50 rpm. Proceed to Test Step 15.

Test Step 15. OBSERVE THE INDICATOR.

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Illustration 19	g00780398
(6) soft start solenoid ("SV01") (7) Enable Solenoid ("SV02") (8) Adjustment for priority flow

1. Observe the indicator on the soft start solenoid ("SV01") when the generator is turning. See illustration 19.

Illustration 20	g00786326
(10) TR106

Expected Result:

The indicator on the connector is OFF.

Results:

• YES - The indicator on the connector of the soft start solenoid ("SV01") is OFF. Proceed to Test Step 16.

• NO - The indicator on the connector of the soft start solenoid ("SV01") is ON. When "SV01" is ON, hydraulic oil is bypassed from the hydraulic motor for the generator. The oil is redirected to the reservoir. The speed of the generator is cut in half under no load conditions. Generator output varies directly with rpm.

  Repair: The timing relay (soft start) ("TR106") has failed. Press the drop switch on the LH joystick. Turn OFF the key start switch and the disconnect switch. Replace the timing relay (soft start) ("TR106"). Verify that the rpm and the generator output is back to the correct range.

  STOP

Test Step 16. CHECK THE STATUS OF THE INDICATOR.

1. Press the drop switch on the LH joystick.

Note: Never turn OFF the ignition key and never open the disconnect switch when the system is in the lift mode in order to prevent possible damage to the controller.

2. . Turn the disconnect switch to the OFF position.

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Illustration 21	g00717550
Technique for opening the control panel

3. Open the Control panel by squeezing the tab on the disconnect switch between the thumb and the finger. See illustration 21.

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Illustration 22	g00780336
Inside of the Control Panel for the Magnet (4) Screw.

4. Remove the cover for the PLC by removing the four screws (4) .

5. Turn the disconnect switch ("DISC 101") to the ON position.

   Note: The key start switch must be ON, but the engine does not need to be running.

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Illustration 23	g00782035
Location of Power on the PLC

6. Observe the green LED indicator ("POWER") on the PLC.

Expected Result:

The green LED indicator ("POWER") is ON.

Results:

• YES - The green LED indicator ("POWER") is ON. Proceed to Test Step 17.

• NO - The green LED indicator ("POWER") is OFF. Proceed to Test Step 21.

Test Step 17. CHECK THE STATUS OF THE INDICATOR.

1. Observe the green LED indicator ("RUN") on the PLC.

Expected Result:

The green LED indicator ("RUN") is ON.

Results:

• YES - The green LED indicator ("RUN") is ON. Proceed to Test Step 18.

• NO - The green LED indicator ("RUN") is OFF.

  Repair: Turn the key start switch to the OFF position. Turn the disconnect switch to the OFF position. Replace the PLC. See Testing and Adjusting, "Programmable Logic Controller - Replace".

  STOP

Test Step 18. CHECK THE STATUS OF THE INDICATOR.

1. Observe the red LED indicator ("FAULT") on the PLC.

Expected Result:

The red LED indicator ("FAULT") is OFF.

Results:

• YES - The red LED indicator ("FAULT") is OFF. Proceed to Test Step 20.

• NO - The red LED indicator ("FAULT") is ON. The voltage to the PLC is too low or the PLC has failed. Proceed to Test Step 19.

Test Step 19. MEASURE THE VOLTAGE.

1. Set the digital multimeter to the scale for DCV. Connect the positive lead of the multimeter on terminal "110" on the terminal strip. Connect the negative lead of the multimeter on terminal "110C" on the terminal strip. Refer to the Electrical System Schematic, RENR3125.

2. Measure the voltage.

Expected Result:

The voltage should measure more than 21 DCV.

Results:

• YES - The voltage measures more than 21 DCV.

  Repair: The PLC has failed. Turn the key start switch to the OFF position. Turn the disconnect switch to the OFF position. Replace the PLC. See Testing and Adjusting, "Programmable Logic Controller - Replace".

  STOP

• NO - The voltage does not measure more than 21 DCV.

  Repair: The batteries for the machine are low. Recharge the batteries. Verify that the "FAULT" indicator is OFF.

  STOP

Test Step 20. CHECK THE STATUS OF THE INDICATOR.

Illustration 24	g00790678

1. Observe the red LED indicator ("FORCE") on the PLC.

Expected Result:

The red LED indicator ("FORCE") is OFF.

Results:

• YES - The red LED indicator ("FORCE") is OFF. Proceed to Test Step 29.

• NO - The red LED indicator ("FORCE") is ON.

  Repair: The PLC has failed. Turn the key start switch to the OFF position. Turn the disconnect switch to the OFF position. Replace the PLC. See Testing and Adjusting, "Programmable Logic Controller - Replace".

  STOP

Test Step 21. MEASURE THE VOLTAGE.

Illustration 25	g00786196
Terminal Strip

1. The key start switch must be ON, but the engine does not need to be running.

2. Set the digital multimeter to the scale for DCV.

3. Connect the positive lead of the multimeter to the "DC24V" terminal on the PLC (wire 110). Connect the negative lead of the multimeter to the "DC In Com" terminal on the PLC (wire 110C). Refer to the Electrical System Schematic, RENR3125.

4. Measure the voltage.

Expected Result:

The voltage measures 24 DCV.

Results:

• YES - The voltage measures 24 DCV.

  Repair: The PLC has failed. Turn the key start switch to the OFF position. Turn the disconnect switch to the OFF position. Replace the PLC. See Testing and Adjusting, "Programmable Logic Controller - Replace".

  STOP

• NO - The voltage does not measure 24 DCV. Proceed to Test Step 22.

Test Step 22. MEASURE THE VOLTAGE.

1. Set the digital multimeter to the scale for DCV.

2. Connect the positive lead of the multimeter to terminal 101E on the terminal strip. Connect the negative lead of the multimeter to 102C. Refer to the Electrical System Schematic, RENR3125.

3. Measure the voltage.

Expected Result:

The voltage should measure 24 DCV.

Results:

• YES - The voltage measures 24 DCV.

  Repair: "FU108" has failed. Turn the disconnect switch to the OFF position. Replace the fuse with a fuse that has the same rating. Remove "TVS109" from the panel. Measure the resistance of "TVS109". If the resistance is less than 5 ohms then replace "TVS109". Resume normal machine operation.

  STOP

• NO - The voltage does not measure 24 DCV. Proceed to Test Step 23.

Test Step 23. MEASURE THE VOLTAGE.

1. Set the digital multimeter to the scale for DCV.

2. Connect the positive lead of the multimeter to terminal 101B on the terminal strip. Connect the negative lead of the multimeter to 102C. Refer to the Electrical System Schematic, RENR3125.

3. Measure the voltage.

Expected Result:

The voltage should measure 24 DCV.

Results:

• YES - The voltage measures 24 DCV.

  Repair: "FU-A" has failed. Turn the disconnect switch to the OFF position. Replace the fuse with a fuse that has the same rating. Remove "TVS-A" from the panel. Measure the resistance of "TVS-A". If the resistance is less than 5 ohms then replace "TVS-A". Resume normal machine operation.

  STOP

• NO - The voltage does not measure 24 DCV. Proceed to Test Step 24.

Test Step 24. MEASURE THE VOLTAGE.

Illustration 26	g00786196
Terminal Strip

1. Set the digital multimeter to the scale for DCV.

2. Connect the positive lead of the multimeter to "FU101" (wire 101A). Connect the negative lead of the multimeter to "FU102" (wire 102B). Refer to the Electrical System Schematic, RENR3125.

3. Measure the voltage.

Expected Result:

The voltage should measure 24 DCV.

Results:

• YES - The voltage measures 24 DCV.

  Repair: Either "FU101" or "FU102" has failed. Turn the key start switch to the OFF position. Turn the disconnect switch to the OFF position. Remove "FU101" and "FU102". Measure the resistance of each fuse. Replace the fuse that has more than 1 ohm of resistance. Resume normal machine operation.

  STOP

• NO - The voltage does not measure 24 DCV. Proceed to Test Step 25.

Test Step 25. MEASURE THE VOLTAGE.

1. Set the digital multimeter to the scale for DCV.

2. Connect the positive lead of the multimeter to wire 101-GN on the disconnect switch. Connect the negative lead of the multimeter to wire 102-BK on the disconnect switch. Refer to the Electrical System Schematic, RENR3125.

3. Measure the voltage.

Expected Result:

The voltage should measure 24 DCV.

Results:

• YES - The voltage measures 24 DCV.

  Repair: The disconnect switch has failed. Turn the key start switch to the OFF position. Turn the disconnect switch to the OFF position. Replace the disconnect switch. Verify that the new switch corrects the problem.

  STOP

• NO - The voltage does not measure 24 DCV. Proceed to Test Step 26.

Test Step 26. CHECK THE BREAKER.

Check the circuit breaker for the generator (30 amp) and check the main circuit breaker for the machine. Refer to the Electrical System Schematic, RENR3125.

Expected Result:

The circuit breaker for the generator is tripped or the main breaker is tripped.

Results:

• YES - The circuit breaker for the generator is tripped or the main breaker is tripped.

  Repair: Reset the circuit breaker. Verify that the problem has been corrected.

  STOP

• NO - The circuit breaker for the generator is not tripped or the main breaker is not tripped. Proceed to Test Step 27.

Test Step 27. MEASURE THE VOLTAGE.

1. Set the digital multimeter to the scale for DCV.

2. Connect the positive lead of the multimeter to wire 112-PU on the main relay. Connect the negative lead of the multimeter to ground. Refer to the Electrical System Schematic, RENR3125.

3. Measure the voltage.

Expected Result:

The voltage should measure 24 DCV.

Results:

• YES - The voltage measures 24 DCV.

  Repair: The problem does not exist at this time. The initial problem was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation.

  STOP

• NO - The voltage does not measure 24 DCV. Proceed to Test Step 28.

Test Step 28. MEASURE THE VOLTAGE.

1. Ensure that the key start switch is on.

2. Set the digital multimeter to the scale for DCV.

3. Connect the positive lead of the multimeter to wire 308-YL on the main relay. Connect the negative lead of the multimeter to 200-BK (ground) on the main relay. Refer to the Electrical System Schematic, RENR3125.

4. Measure the voltage.

Expected Result:

The voltage should measure 24 DCV.

Results:

• YES - The voltage measures 24 DCV.

  Repair: The main relay has failed. Replace the main relay. Resume normal machine operation.

  STOP

• NO - The voltage does not measure 24 DCV.

  Repair: The key start switch has failed. Replace the key start switch. Resume normal machine operation.

  STOP

Test Step 29. CHECK THE INPUT.

Illustration 27	g00790683

1. The grapple/magnet switch must be in the MAGNET position. The hydraulic lockout lever must be in the unlocked position.

2. The operator must hold the lift switch on the RH joystick. Observe the LED indicator for input 4. Also, observe the LED indicator for output 4.

Expected Result:

The LED indicator for input 4 and the LED indicator for output 4 are ON.

Results:

• BOTH - The LED indicator for input 4 and the LED indicator for output 4 are ON.

  Repair: The problem has not been corrected. Exit this procedure. Enter this procedure again.

  STOP

• INPUT 4 ONLY - The LED indicator for input 4 is ON.

  Repair: The PLC has failed. Turn the key start switch to the OFF position. Turn the disconnect switch to the OFF position. Replace the PLC. See Testing and Adjusting, "Programmable Logic Controller - Replace".

  STOP

• NONE - Neither of the LED indicators are ON. Proceed to Test Step 30.

Test Step 30. MEASURE THE VOLTAGE.

Illustration 28	g00786326
(10) TR106

1. Set the digital multimeter to the scale for DCV.

2. Connect the positive lead of the multimeter to wire 117 on the PLC. Connect the negative lead of the multimeter to ground. Refer to the Electrical System Schematic, RENR3125.

3. Measure the voltage.

Expected Result:

The voltage should measure 24 DCV.

Results:

• YES - The voltage measures 24 DCV.

  Repair: The PLC has failed. Turn the key start switch to the OFF position. Turn the disconnect switch to the OFF position. Replace the PLC. See Testing and Adjusting, "Programmable Logic Controller - Replace".

  STOP

• NO - The voltage does not measure 24 DCV. Proceed to Test Step 31.

Test Step 31. MEASURE THE VOLTAGE.

1. Set the digital multimeter to the scale for DCV.

2. Disconnect the harness connector for the grapple/magnet switch. The connector is located in the cab. Refer to the Electrical System Schematic, RENR3125.

3. At the connector for the grapple/magnet switch, connect the positive lead of the multimeter to wire J718-WH. Connect the negative lead of the multimeter to ground. Refer to the Electrical System Schematic, RENR3125.

4. Measure the voltage while the lift switch on the controller is pressed.

Expected Result:

The voltage should measure 24 DCV.

Results:

• YES - The voltage measures 24 DCV.

  Repair: The wires between the grapple/magnet switch and the PLC have failed. Turn the key start switch to the OFF position. Turn the disconnect switch to the OFF position. Replace the harness.

  STOP

• NO - The voltage does not measure 24 DCV. Reconnect the connector for the grapple/magnet switch. Proceed to Test Step 32.

Test Step 32. MEASURE THE VOLTAGE.

1. Set the digital multimeter to the scale for DCV.

2. At the lift switch, connect the positive lead of the multimeter to wire 549-PK. Connect the negative lead of the multimeter to ground. Refer to the Electrical System Schematic, RENR3125.

3. Measure the voltage while the lift switch is being pressed.

Expected Result:

The voltage should measure 24 DCV.

Results:

• YES - The voltage measures 24 DCV.

  Repair: The grapple/magnet switch has failed. Turn the key start switch to the OFF position. Turn the disconnect switch to the OFF position. Replace the grapple/magnet switch.

  STOP

• NO - The voltage does not measure 24 DCV. Proceed to Test Step 33.

Test Step 33. MEASURE THE VOLTAGE.

1. Set the digital multimeter to the scale for DCV.

2. At the lift switch, connect the positive lead of the multimeter to wire J704-WH. Connect the negative lead of the multimeter to ground. Refer to the Electrical System Schematic, RENR3125.

3. Measure the voltage.

Expected Result:

The voltage should measure 24 DCV.

Results:

• YES - The voltage measures 24 DCV.

  Repair: The lift switch has failed. Turn the key start switch to the OFF position. Turn the disconnect switch to the OFF position. Replace the lift switch.

  STOP

• NO - The voltage does not measure 24 DCV. Proceed to Test Step 34.

Test Step 34. MEASURE THE VOLTAGE.

1. Set the digital multimeter to the scale for DCV.

2. At the fuse for the hydraulic lock solenoid, connect the positive lead of the multimeter to wire 151-GN. Connect the negative lead of the multimeter to ground. Refer to the Electrical System Schematic, RENR3125.

3. Measure the voltage.

Expected Result:

The voltage should measure 24 DCV.

Results:

• YES - The voltage measures 24 DCV. Proceed to Test Step 37.

• NO - The voltage does not measure 24 DCV. Proceed to Test Step 35.

Test Step 35. MEASURE THE VOLTAGE.

1. Set the digital multimeter to the scale for DCV.

2. At the neutral start switch, connect the positive lead of the multimeter to wire 151-GN. Connect the negative lead of the multimeter to ground. Refer to the Electrical System Schematic, RENR3125.

3. Measure the voltage.

Expected Result:

The voltage should measure 24 DCV.

Results:

• YES - The voltage measures 24 DCV.

  Repair: The relay for the hydraulic lock solenoid has failed. Turn the key start switch to the OFF position. Turn the disconnect switch to the OFF position. Replace the relay for the hydraulic lock solenoid.

  STOP

• NO - The voltage does not measure 24 DCV. Proceed to Test Step 36.

Test Step 36. MEASURE THE VOLTAGE.

1. Set the digital multimeter to the scale for DCV.

2. At the neutral start switch, connect the positive lead of the multimeter to wire 151-GN. Connect the negative lead of the multimeter to ground. Refer to the Electrical System Schematic, RENR3125.

3. Measure the voltage.

Expected Result:

The voltage should measure 24 DCV.

Results:

• YES - The voltage measures 24 DCV.

  Repair: The neutral start switch has failed. Turn the key start switch to the OFF position. Turn the disconnect switch to the OFF position. Replace the neutral start switch.

  STOP

• NO - The voltage does not measure 24 DCV. Proceed to Test Step 37.

Test Step 37. MEASURE THE VOLTAGE.

1. Set the digital multimeter to the scale for DCV.

2. At the fuse for the hydraulic lock solenoid, connect the positive lead of the multimeter to wire 189-RD. Connect the negative lead of the multimeter to ground. Refer to the Electrical System Schematic, RENR3125.

3. Measure the voltage.

Expected Result:

The voltage should measure 24 DCV.

Results:

• YES - The voltage measures 24 DCV.

  Repair: The fuse for the hydraulic lock solenoid has failed. Turn the key start switch to the OFF position. Turn the disconnect switch to the OFF position. Replace the fuse for the hydraulic lock solenoid.

  STOP

• NO - The voltage does not measure 24 DCV. Proceed to Test Step 38.

Test Step 38. MEASURE THE VOLTAGE.

1. Set the digital multimeter to the scale for DCV.

2. At the timer relay, connect the positive lead of the multimeter to wire 177-RD. Connect the negative lead of the multimeter to ground. Refer to the Electrical System Schematic, RENR3125.

3. Measure the voltage.

Expected Result:

The voltage should measure 24 DCV.

Results:

• YES - The voltage measures 24 DCV.

  Repair: The timer relay has failed. Turn the key start switch to the OFF position. Turn the disconnect switch to the OFF position. Replace the timer relay.

  STOP

• NO - The voltage does not measure 24 DCV. Proceed to Test Step 39.

Test Step 39. MEASURE THE VOLTAGE.

1. Set the digital multimeter to the scale for DCV.

2. At the main breaker for the machine, connect the positive lead of the multimeter to wire 101-RD. Connect the negative lead of the multimeter to ground. Refer to the Electrical System Schematic, RENR3125.

3. Measure the voltage.

Expected Result:

The voltage should measure 24 DCV.

Results:

• YES - The voltage measures 24 DCV.

  Repair: The main breaker has failed. Turn the key start switch to the OFF position. Turn the disconnect switch to the OFF position. Replace the main breaker.

  STOP

• NO - The voltage does not measure 24 DCV.

  Repair: There is a poor connection or the wires between the main breaker and the batteries have failed. Turn the key start switch to the OFF position. Turn the disconnect switch to the OFF position. Clean the terminals and reconnect the terminals for the batteries and for the main breaker. If the problem still exists, replace the cables between the main breaker and the batteries.

  STOP

Test Step 40. MEASURE THE EXCITATION VOLTAGE OF THE SHUNT FIELD

Illustration 29	g00786196
Terminal Strip

1. Set the digital multimeter to the scale for DCV.

2. Connect the positive lead of the multimeter to terminal 101D in the control panel for the generator. Connect the negative lead of the multimeter to terminal 102D in the control panel for the generator. Refer to the Electrical System Schematic, RENR3125.

3. Measure the voltage while the lift switch is pressed.

Expected Result:

The voltage measurement is battery voltage.

Note: The voltage must be measured within 3 seconds of pressing the lift switch. After 3 seconds, the voltage is reduced to half the battery voltage.

Results:

• YES - The voltage measurement is battery voltage. Proceed to Test Step 41.

• NO - The voltage does not measure battery voltage. Proceed to Test Step 43.

Test Step 41. MEASURE THE VOLTAGE.

1. Press the drop switch.

2. Set the digital multimeter to the scale for DCV.

3. Connect the positive lead of the multimeter to terminal 101D in the control panel for the generator. Connect the negative lead of the multimeter to terminal 102D in the control panel for the generator. Refer to the Electrical System Schematic, RENR3125.

4. Measure the voltage while the lift switch is pressed.

Expected Result:

The voltage is half the battery voltage at 3 seconds after you press the lift switch.

Results:

• YES - The voltage is half the battery voltage at 3 seconds after you press the lift switch.

  Repair: The generator has failed. Turn the key start switch to the OFF position. Turn the disconnect switch to the OFF position. Replace the generator.

  STOP

• NO - The voltage is not half the battery voltage at 3 seconds after you press the lift switch. Proceed to Test Step 42.

Test Step 42. CHECK FOR AN OPEN CIRCUIT.

1. Press the drop switch on the LH joystick.

2. Turn the key start switch to the OFF position. Turn the disconnect switch to the OFF position.

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Illustration 30	g00722341
Connections for the generator

3. Remove the cover over the connections for the generator.

4. Remove the tape that is on wire F1 and wire F4.

5. Set the multimeter to the selection for resistance. Connect the positive lead to wire F1 and connect the negative lead to wire F4.

6. Measure the resistance.

Expected Result:

The resistance should measure 0.5 to 2 ohms.

Results:

• YES - The resistance measures 0.5 to 2 ohms.

  Repair: There is an open circuitin one of the wires from the controller to the generator. Disconnect wire F1 and wire F4 from the generator. Disconnect wire 101D and wire 102D from the control panel. Repair the wire or replace the wire that has failed.

  STOP

• NO - The resistance does not measure 0.5 to 2 ohms.

  Repair: The shunt field of the generator has failed. Replace the generator.

  STOP

Test Step 43. MEASURE THE VOLTAGE.

Illustration 31	g00786196
Terminal Strip

1. Set the digital multimeter to the scale for DCV.

2. Connect the positive lead of the multimeter to terminal 101C in the control panel for the generator. Connect the negative lead of the multimeter to terminal 102D in the control panel for the generator. Refer to the Electrical System Schematic, RENR3125.

3. Measure the voltage while the lift switch is pressed.

Expected Result:

The voltage should measure battery voltage.

Results:

• YES - The voltage measurement is battery voltage. Proceed to Test Step 44.

• NO - The voltage does not measure battery voltage. Proceed to Test Step 45.

Test Step 44. MEASURE THE RESISTANCE.

1. Press the drop switch on the LH joystick.

2. Turn the key start switch to the OFF position. Turn the disconnect switch to the OFF position.

3. Remove wire F1 from terminal 101D.

4. Set the multimeter to the selection for resistance. Record the resistance of resistor "101A". Record the resistance of resistor "101B". Refer to the Electrical System Schematic, RENR3125.

Expected Result:

The resistance that is measured for resistor "101A" is 1.0 ohm. The resistance that is measured for resistor "101B" is 1.5 ohms.

Results:

• YES - The resistance that is measured for resistor "101A" is 1.0 ohm. The resistance that is measured for resistor "101B" is 1.5 ohms.

  Repair: There is an open circuit in the wiring from the power resistors to the terminal strip. Repair the wires or replace the wires that have failed.

  STOP

• NO - One of the resistance values that was measured is incorrect.

  Repair: A power resistor has failed. Replace the resistor that had a high resistance measurement (open).

  STOP

Test Step 45. CHECK THE SOLID STATE RELAY

Note: Solid state relays are "SSR170" and "SSR171". These relays control the excitation of the shunt field of the generator. This occurs during the lift mode. Therefore, both relays must conduct in lift mode in order to provide battery voltage to terminals "101C" and "102D". The following procedure tests the relays in order to determine the relay that has failed. Refer to the Electrical System Schematic, RENR3125.

Illustration 32	g00782043
(11) Terminal Strip (12) "SSR-170" Relay (Lift) (13) "SSR-171" Relay (Lift) (14) "SSR-172" Relay (Drop) (15) "SSR-173" Relay (Drop)

Illustration 33	g00786196
Terminal Strip

1. Press the drop switch on the LH joystick.

2. Set the digital multimeter to the scale for DCV.

3. Connect the positive lead of the multimeter to terminal 101C in the control panel for the generator. Connect the negative lead of the multimeter to terminal 102D in the control panel for the generator. Refer to the Electrical System Schematic, RENR3125.

4. Measure the voltage while the lift switch is pressed.

Expected Result:

The voltage should measure battery voltage.

Results:

• YES - The voltage measures battery voltage. "SSR170" is working correctly. Proceed to Test Step 46.

• NO - The voltage does not measure battery voltage.

  Repair: "SSR170" has failed. Press the drop switch. Turn the key start switch to the OFF position. Turn the disconnect switch to the OFF position. Replace "SSR170". Verify that the new relay corrects the problem.

  STOP

Test Step 46. CHECK THE SOLID STATE RELAY

Illustration 34	g00782043
(11) Terminal Strip (12) "SSR-170" Relay (Lift) (13) "SSR-171" Relay (Lift) (14) "SSR-172" Relay (Drop) (15) "SSR-173" Relay (Drop)

1. Press the drop switch on the LH joystick.

2. Set the digital multimeter to the scale for DCV.

3. Connect the positive lead of the multimeter to terminal 101B in the control panel for the generator. Connect the negative lead of the multimeter to terminal 102D in the control panel for the generator.

4. Measure the voltage while the lift switch is pressed.

Expected Result:

The voltage should measure battery voltage.

Results:

• YES - The voltage measures battery voltage. "SSR171" is working correctly.

  Repair: The problem does not exist at this time. The initial problem was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation.

  STOP

• NO - The voltage does not measure battery voltage.

  Repair: "SSR171" has failed. Press the drop switch. Turn the key start switch to the OFF position. Turn the disconnect switch to the OFF position. Replace "SSR171". Verify that the new relay corrects the problem.

  STOP