GEAR SET-BEVEL 9R8035 - Caterpillar

Illustration 9 g01368468
Operating States of the loaded Generator (Output Voltage with connected magnet) (t1) Boost Voltage time period (t2) Operating Voltage time period (t3) Drop Voltage time period (t4) Magnet OFF Voltage time period (A) Boost voltage 260 +/- 10VDC (B) Operating voltage 230 +/- 5VDC (C) Drop voltage -170 +/- 10VDCTurn the magnet ON.After the Boost period of approximately 2 seconds, the Boost timer will turn off. Measure the Output (Operating) Voltage (t2) from Pin 11 to 12 of the Terminal Block (11) .Expected Result:The Output (Operating) Voltage (t2) is 230 5 VDC.Results:
OK - The Output (Operating) Voltage is 230 5 VDC. Proceed to Test Step 33.
NOT OK - The Output (Operating) Voltage is not 230 5 VDC.Repair: Refer to Systems Operation Troubleshooting Testing and Adjusting, RENR8031, "Generator Set - Test and Adjust". Adjust the Variable Resistor R1 (3) in order to set Output (Operating) Voltage (t2) to 230 5 VDC. Proceed to Test Step 33.Test Step 33. Check the Voltage of the Shunt Field at the Junction Box of the Generator.Press the Magnet Lift/Drop Switch on the joystick in order to activate the magnet.Measure the voltage between Terminals F1 (22) and F2 (23) of the Junction Box on the generator. This is the voltage across the Shunt Field of the Generator.Expected Result:The voltage is between 5 and 30VDC.Results:
OK - The voltage is between 5 and 30VDC. Proceed to Test Step 34.
NOT OK - The Voltage is not between 5 and 30VDC.Repair: Repair the machine harness wiring from the Magnet Controller to the Terminals F1 (22) and F2 (23) in the Junction Box on the Generator.STOPTest Step 34. Visually check the Generator Brushes
Illustration 10 g01116247
View of Generator Front Brush (Cover Removed)
Illustration 11 g01116269
View of Generator Rear Brush (Cover Removed)Turn off the Generator. Turn off the engine. Remove the front and rear brush covers on the generator. Inspect the brushes and wire leads to the brushes. Refer to Illustrations 10 and 11Expected Result:The brushes are not damaged. The wire leads are connected to the brushes.Results:
OK - The brushes are not damaged. The wire leads are connected to the brushes. Proceed to Test Step 35.
NOT OK - The brushes are damaged or the wire leads are not connected to the brushes.Repair: Replace the brushes.STOPTest Step 35. Check the Resistance of the Magnet Cable
Illustration 12 g01116161
Junction Box Terminal Connections (15 kW machine) (22) Terminal F1 (23) Terminal F2 (24) Terminal B2 (25) Terminal A1 (26) Not used (27) Terminal A2 (28) Cable to Magnet (29) Cable to Controller
Illustration 13 g01116173
Junction Box Terminal Connections (12.5 kW machine) (22) Terminal F1 (23) Terminal F2 (24) Terminal B2 (25) Terminal A1 (26) Not used (27) Terminal A2 (28) Cable to Magnet (29) Cable to ControllerNote: The difference in the Junction Boxes is at the Cable to the magnet (28). The 15 kW system has one larger wire to each of the terminal connections. The 12.5 kW system has two smaller wires to each of the terminal connections. The terminal connections are otherwise the same regardless of the