Service Training MALAGA

300B Hydraulic Excavators

AUXILIARY HYDRAULIC CONTROL

Francis NOV 97

COMBINED CIRCUIT
NEUTRAL (Single Action)
2nd Speed Hammer
117-8919 Medium Press Circ 131-9203 L970 - GY Hammer Press. Switch 37

3T-3132

Eng / Pump Ctrl

LHS
PILOT PUMP Lo 1114878 Hi 200 - BK

RHS

AUXILIARY CONTROL VALVE

106-0179

2 Speed Hammer

Aux Hyd Contr

A849 - OR A850 - WH 950 - BR 585 - YL 951 - PK

198 - PK 961 - BR 952 - OR 546 - BU 547 - OR 548 - GY 549 - PK 954 - GN

BOOM STICK BUCKET

191 - WH

CHAPTER : Auxiliary Hydraulic Control

SWING

MAIN PUMPS NFC NFC

AC1

AC2

PILOT PUMP

Page: 2

Option
116-3413

111-9916

121-1491

121-1491

AUX. PILOT MANIFOLD

300B COMBINED CIRCUIT

2nd Speed Hammer

HAMMER ACTIVATED
117-8919 3T-3132 Medium Press Circ 131-9203 L970 - GY Hammer Press. Switch 37

Eng / Pump Ctrl

LHS
PILOT PUMP Lo 1114878 Hi 200 - BK

RHS

ATTACHMENT CONTROL VALVE

106-0179

2 Speed Hammer

Aux Hyd Contr

A849 - OR A850 - WH 950 - BR 585 - YL 951 - PK

198 - PK 961 - BR 952 - OR 546 - BU 547 - OR 548 - GY 549 - PK 954 - GN

BOOM STICK BUCKET

191 - WH

SWING

CHAPTER : Auxiliary Hydraulic Control

MAIN PUMPS NFC NFC

PILOT PUMP

Option
116-3413

Page: 3

111-9916

121-1491

121-1491

AUX. PILOT MANIFOLD

NOTE: The hammer mode must be activated with Power + Mode and Boom Priority selected

300B COMBINED CIRCUIT

2nd Speed Hammer

HAMMER/BOOM ACTIVATED
117-8919 3T-3132 Medium Press Circ 131-9203 L970 - GY Hammer Press. Switch 37

Eng / Pump Ctrl

LHS
PILOT PUMP Lo 1114878 Hi 200 - BK

RHS

AUXILIARY CONTROL VALVE

106-0179

2 Speed Hammer

Aux Hyd Contr

A849 - OR A850 - WH 950 - BR 585 - YL 951 - PK

198 - PK 961 - BR 952 - OR 546 - BU 547 - OR 548 - GY 549 - PK 954 - GN

BOOM STICK BUCKET

191 - WH

SWING

CHAPTER : Auxiliary Hydraulic Control

MAIN PUMPS

NFC NFC

PILOT PUMP

Option
116-3413

Page: 4

111-9916

121-1491

121-1491

AUX. PILOT MANIFOLD

NOTE: The hammer mode must be activated with Power + Mode and Boom Priority selected

300B COMBINED CIRCUIT

Medium Press Attach Ctrl Vl
3T-3132

DOUBLE ACTION
117-8919 Medium Press Circ 131-9203 L970 - GY Hammer Press. Switch 37

Eng / Pump Ctrl

LHS
PILOT PUMP Lo 1114878 Hi 200 - BK

RHS

ATTACHMENT CONTROL VALVE

106-0179

2 Speed Hammer

BOOM STICK BUCKET

191 - WH

SWING

CHAPTER : Auxiliary Hydraulic Control

MAIN PUMPS NFC NFC

Aux Hyd Contr

PILOT PUMP

Option
116-3413

Page: 5

111-9916

121-1491

121-1491

AUX. PILOT MANIFOLD

MEDIUM PRESSURE CIRCUIT (Neutral)

Medium Press Attach Ctrl Vl
3T-3132

A
117-8919

250
A B C 198 - PK Lo 1114878 961 - BR 952 - OR 546 - BU 547 - OR 548 - GY 549 - PK 954 - GN A849 - OR A850 - WH 950 - BR 585 - YL

250

LHS
PILOT PUMP

RHS

200 - BK

106-0179 (ATCH VAL) Hi 200 - BK 191 - WH

131-9203

CHAPTER : Auxiliary Hydraulic Control

200 - BK

Aux Hyd Contr

A847 - YL A848 - PK To F/C aux prop. sol. To AC1 aux sol. To AC2 aux sol.

175 LS

VALVE GROUP 125-8075

Page:
L970 - GY

Eng / Pump Ctrl

37 AUX PUMP 132-5975

Hammer Press. Switch

MEDIUM PRESSURE CIRCUIT (Activated)

Medium Press Attach Ctrl Vl
3T-3132

A
117-8919

250
A B C

250

LHS
PILOT PUMP

RHS

106-0179 (ATCH VAL) Lo 1114878 Hi 200 - BK 191 - WH

131-9203

CHAPTER : Auxiliary Hydraulic Control

Aux Hyd Contr LS

175

To F/C aux prop. sol. To AC1 aux sol. To AC2 aux sol.

VALVE GROUP 125-8075

Page:
L970 - GY

Eng / Pump Ctrl

37 AUX PUMP 132-5975

Hammer Press. Switch

CHAPTER : Auxiliary Hydraulic Control

AUXILIARY DISPLA PANEL

ARROW KEY

ENTER KEY

PLUS KEY

MINUS KEY

" ++", "-","+","--", Then press enter key

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CHAPTER : Auxiliary Hydraulic Control

AUXILIARY HYDRAULIC CONTROLLER

(122-9897)

When the controller in "ON", the first information displayed is the version of the controller. Example : __2.10_

NB. In each major change (software or hardware) that will affect the operation of the controller, the left side digit will be increased. In each minor changes, the digits on the right will be increased.

The controller "Display/Keypad" has the following modes: - Active mode (Aux/Hyd controller is operating) - Inactive mode (Aux/Hyd controller is not operating) - Programming mode

ACTIVE MODE During the Aux/Hyd controller operation, the Display will visualize the selected working mode. The Aux/Hyd controller has 4 different working modes:

1 2 3 4

L H L H

1 1 2 2

The 4 different working mode are combined as follows: 1 _ _ _ L 1 = Low Mode One Way 2 _ _ _ H 1 = High Mode One Way 3 _ _ _ L 2 = Low Mode Two Way 4 _ _ _ H 2 = High Mode Two Way

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CHAPTER : Auxiliary Hydraulic Control

AUXILIARY HYDRAULIC CONTROLLER

(122-9897) INACTIVE MODE

- Number of hours the tool has already accomplished in that working mode. - Operating engine speed set up for that working mode. - Operating flow set up for that working mode. To visualize all these information the Arrow Key must be pushed. The first information shown on the display will be the number of ours of the current active working mode. Pressing the Arrow Key again, will display the next operating engine speed information. Pressing The Arrow Key again, the operating flow will be displayed.

Example : Active Working Mode

2 2 2 2 3 3 3 4 4 4 1 1 1 2 h E F h E F h E F h E F h X Y n X Y n X Y n X Y n X X Y n X Y n X Y n X Y n X

H X H H X L L X H H X L L X

1 X 1 1 X 2 2 X 2 2 X 1 1 X

NB. Use the arrow key to visualize all settings by scrolling down. Page: 10

CHAPTER : Auxiliary Hydraulic Control

AUXILIARY HYDRAULIC CONTROLLER

(122-9897) PARAMETERS ADJUSTMENT

The engine speed parameters can be set between 01 and 10 (speed dial position). The operating flow parameters can be set between 00 and 99.

DISPLAY WINDOW Engine speed parameters display

Operating flow parameters

As an example we have recorded on a 325B the following flow values. The engine speed has been set at dial 9 and the machine in One Way configuration.

Flow param. 10 20 25 30 35 40 45 50 55 60

Flow Ltr/min 102 151 177 198 215 234 262 297 323 325

Sys Press kPa 15000 15300 15000 15100 15000 14900 15100 14800 15100 15200

NFC Press kPa 3081 2693 2504 2328 2162 2007 1839 1696 1550 1410 NOTE. The above table should be considered as reference only. As the Aux/Hyd controller is regulating the pump flow through the NFC pressure, it is not guarantee that each machine will have the same flow for the same flow param. setting.

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11

CHAPTER : Auxiliary Hydraulic Control

TESTING WITHIN THE PROGRAMMING MODE

The adequate flow and engine speed parameters must be adjusted within the programming mode to meet the auxiliary tool requirements. In most of the cases, the machine will probably have to be tested prior to recording these values. The programming mode enables the machine to be tested without living the mode, the Keypad remains active and the Display still visualizing whether the flow or engine speed parameters during the Aux/Hyd controller operation. The best practice will be within the programming mode to set first the engine speed to the desire value and then, increase the flow parameters step by step starting from the minimum value, testing each of the values until the requested flow is reached. (Ref. to Hammer installation procedure)

ERROR CODES: Error 1 : open circuit in NFC proportional reducing valve. Error 2 : Aux/Hyd Controller NFC proportional reducing valve output is short grounded. Error 3 : Aux/Hyd Controller AC1 or AC2 output are short - grounded. (AC1 and AC2 are ON/OFF solenoids) Error 4 : Aux/Hyd Controller HAM2 R1 or R2 outputs are short - grounded.

Error 5 : Aux/Hyd Controller detects malfunction of the Activation Pressure Switch . The pressure switch is located on the PTA port of the auxiliary control valve. When ERROR 5 is displayed, maximum pressure is sent to the NFC port for minimum flow output. NOTE. The display of the Error-Codes has priority over the rest of the display codes, but does not affect the function of the Aux/Hyd Controller. Several Error-Codes can appear at the same time, the Aux/Hyd Controller will display on the screen the last Error-Code detected. The Error 1 and 2 can appear in both active or inactive modes. The error 2 and 4 appear only when the Aux/Hyd Controller is operating. As the Aux/Hyd Controller is continuously checking the NFC proportional reducing valve signal, the Error 1 and 2 will disappear automatically when the problems are solved. The Error 3 and 4 will disappear at the next Aux/Hyd Controller operation. If one or several Error-Codes are detected, start to fix the firs Error-Code displayed, then check if additional Error-Codes are displayed. The Aux/Hyd Controller can visualize the errors only one at the time. In case of Errors 1 and 2, the Aux/Hyd Controller will proceed as follows : - Deactivation of AC1 and AC2 output signals. - If for any reason the Activation Pressure SW Signal is "ON", the Aux/Hyd Controller will decrease the engine speed to Dial 1. Page: 12

CHAPTER : Auxiliary Hydraulic Control

AUXILIARY/HYDRAULIC CONTROLLER
DISPLAY WINDOW

WORKING MODE 1234Low Mode One Way High Mode One Way Low Mode Two Way High Mode Two Way

DISPLAY VALUE OF WORKING CONDITIONS - hours - Eng. RPM - Flow

SETTING h- Hours of working Mode E- Engine RPM of Working Mode F- Flow of Working Mode

WORKING MODE COFIGURATION L1 = Low Mode One Way H1 = High Mode One Way L2 = Low Mode Two Way H2 = High Mode Two Way

1 1 1 2 2 PROGRAMMING CHANNELS SELECTION 2 3 3 3 4 4 4 1 1

h E F h E F h E F h E F h E

X X X X X X X X X X X X X X

X X X X X X X X X X X X X X

X L L X H H X L L X H H X H

X 1 1 X 1 1 X 2 2 X 2 2 X 1 Page: 13

CHAPTER : Auxiliary Hydraulic Control

AUXILIARY/HYDRAULIC CONTROLLER
ACCESS TO PROGRAMMING MODE

ARROW KEY

ENTER KEY

PLUS KEY

MINUS KEY

To access the programming mode, press the keys as follow: " ++", "-","+","--", Then press enter key

DISPLAY WINDOW (Could be any other value)

Exemple : Current active mode L 2, change flow parameters from 00 to35. Select first the flow parameters with "Arrow Key" then, press on "+ " or "-" key until you have reached 35

To save the new parameters press "Enter Key" and then "+" Key, the last digit "P" will change from "P" to "S"(Saved) To end the programming mode press "Enter Key" and then "Arrow Key'. TO CHECK THE DIFFERENTS WORK MODE SETTING, PRESS "ARROW KEY", THE DISPLAY WILL SCROLL NOTE: To modify the engine speed and the flow parameters of another working mode, the position of the One Way (Hammer) or Two way (Shear) Ball-Valve Lever and the Rocker Switch (tortoise or rabbit) must be selected. The position must be set to have the desire mode active, the controller authorizes to change only the parameters of the courrent active mode

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14

CHAPTER : Auxiliary Hydraulic Control

300B MAIN HYDRAULIC PUMP

(SECTIONAL VIEW) NFC Adjustment

Pilot Pump

Pilot Pump Drive Gear Barrel

NFC Piston Torque Piston Sleeve

Power Screw Control piston

Control Spring Actuator Spring

Retainer Pin

Piston Port Plate

Actuator

Max Angle Adjust.

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15

CHAPTER : Auxiliary Hydraulic Control

TWO PUMP CONTROLS

(Standby)

NFC Adjustment NFC Pressure

PS Pressure from PRV

NFC Adjustment NFC Pressure

Horsp. Adjus.

Horsp. Adjus.

Actuator Piston

To Control Valve PWM Press sensor Max Angle Adjustment

To Control Valve

Max Angle Adjustment

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16

CHAPTER : Auxiliary Hydraulic Control

TWO PUMP CONTROLS

(2 Pumps Flow)

NFC Adjustment NFC Pressure

PS Pressure from PRV

NFC Adjustment NFC Pressure

Horsp. Adjus.

Horsp. Adjus.

Actuator Piston

To Control Valve PWM Press sensor Max Angle Adjustment

To Control Valve

Max Angle Adjustment

Page:

17