Carrier Setup

Carrier Setup

SSL, Mini-HEX, and Backhoe

Carrier Setup

Non-CAT Carrier

OUT

Test Purposes:
• Verify flow at operating pressure IN

• Verify return line back pressure

• Identify relief crack point
• Identify relief setting in hammer circuit
Carrier Setup

Large HEX Testing and Adjusting

Work Tool Program Calibrations

HEX Work Tool Program

Work Tool Program must be properly programed to prevent Work Tool failure and
provide satisfactory production.

Main Programing Topics

1.One or Two Pump Flow
2.One or Two Way Flow
3.Relief Pressures (Electronic Relief)
4.Flow Settings
5.Multi-Operation Flow Settings
6.Multi-Operation Pressure Settings.
7.Valve Close and Open Times
8.Medium Pressure Rotate Settings
HEX Work Tool Program

1. Two Pump Flow Combine needs to be enabled if required flow to Work Tool
approaches or exceeds capacity of One Pump on the Carrier.

2. One Way/Two Way Valve Mode depends on the Work Tool. One Way brings return
flow directly back to tank while Two Way sends it back through the Main Valve.

a. One Way: Hammers, Compactors

b. Two Way: Shears, Multi-Processors, OPG, Thumbs, Pulverizers

One Way Flow = Lower Back Pressure

HEX Work Tool Program

3. Line Relief Pressures can be programmed through the Work Tool Program if the Reliefs
are Electronic. (Pressure Setting is At Main Pumps)

a. Some Reliefs are only adjustable manually.

b. Hammer Program is generally set at 3200 psi Relief.
c. Demolition Tools are set at 5100 psi, above Main Relief.
d. Relief Pressure at the Work Tool will usually be 200-300
psi less than the Relief Pressure at the Pumps.

If Reliefs are set too low, poor or no HEX Manual Relief

performance of the Work Tool can occur.
HEX Work Tool Program

4. Attachment Valve #1 Flow Setting is programed with the required Flow to the Work
Tool. Recommend 80% of Max for Rental Programs.

5. Attachment Valve #1 Multi-Oper. Additional Flow sends extra Flow to the Work Tool if
another function is activated by the Operator.

Multi-Operation Additional Flow = ZERO for Hammers!

HEX Work Tool Program

6. Multi-Operation Maximum Extend and Retract Pilot Pressures #1 and Combined

control what functions have priority for Supply Flow from the Carrier.

a. 580 psi setting will give Full Flow Priority to the Work Tool
b. 300 psi setting will start to cause the Carrier to take Priority over the
Work Tool.
c. 200 psi setting and lower will give full Priority to the Carrier and
cause Performance issues with the Work Tool.
d. D-Series Excavators usually default with Carrier Priority while E-
Series Excavators are usually default with Work Tool Priority.
e. Most operators prefer Work Tool Priority over Carrier Priority.
f. Very important Setting for Demolition Tools.
HEX Work Tool Program

7. Attachment Valve #1 and #2 Open and Close Times are default set around 0.20
seconds. This is the time it takes to Open the Valve after pressing the button and Close
the Valve after releasing the button.

a. For almost all cases this should be left at the default value.
b. For demolition tools such as a Shear, Close Times can be lowered to 0.05-0.10
seconds if the operator needs better reaction time to prevent jams.
HEX Work Tool Program

8. Attachment Valve #3 Extend and Retract Pressures are to control Flow from a Fixed
Displacement Medium Pressure Pump for Rotate Functions.

a. For a 336 sized Excavator, the Medium Pressure Pump will output around 11
GPM Max.
b. 580 psi setting in the Program, which is the max allowable setting, will cause
the Pump to output 11 GPM.
c. 250 psi setting in the Program will cause the Pump to output around 5 GPM.
d. E-Series Excavators program by Flow Setting, not Pressures as in this D-Series
example.
Carrier Calibrations

Large HEX Testing and Adjusting

Calibrations must be performed to match Carrier

Monitor Settings to Actual Output from Carrier

1. Engine Speed (C & D Series Only)

2. Pilot Pressure
3. Control Inputs
4. Auxiliary Pilot Solenoids
5. Relief Valves
6. Flow

Not Performing or Verifying Calibrations will

increase the chances of Work Tool Failure
Calibrations – Calibration Status ET

Check the Calibration Status

Menu in ET for Updated List of
Completed Calibrations
Calibrations – ET

Calibrations must be completed

in Order below or Carrier will
not function correctly.

Calibration Order
1.Engine Speed (C&D Series)
2.PRV – Power Shift Pressure
3.Modulation Input Calibration
4.PRV – Attachment Valve Pressure
5.PRV – Variable Relief Pressure
6.PRV – Main Pump Flow Limitation
Calibrations – Monitor

Calibrations can also be performed from the Carrier Monitor, but

are more difficult to complete.
Calibrations – Engine Speed

1. The engine speed calibration is critical for proper

machine operation.

2. The machine ECM sends an electrical signal to the

power shift solenoid that is based on engine speed and
the position of the engine speed dial.

3. If the Engine Speed is not calibrated the ECM will send

false information to the power shift solenoid.

C & D Series Carrier Only. E-

Series Carrier and above will not
have this Calibration.
Calibrations - Powershift

If Powershift is not Calibrated, it can be

possible for Flow to not Calibrate correctly

Connect 750 psi

gauge to this port.

Power Shift Test Port 336E Pump Compartment

Calibrations - Controls

Calibrations must be performed when new

joystick or pedal is installed, usually during the
installation of a Work Tool Hydraulic Kit
Calibrations – Attachment Valves

Attachment Valves:

1.One and Two Pump Flow

2.Medium Pressure Rotate

3.Rarely Used (Cab Raiser)

Calibrations must be performed when installed

Test port block for attachment valves in pump

compartment. Use 750 psi gauges.

Smaller machines will have test ports under rear belly

pan.
Calibrations – Relief Valves

Line Relief needs to be checked for accuracy.

1.Close the Return Ball Valve and read the Pump Pressures in the Monitor.
2.Use a Load Sensing Flow Meter and close the circuit and read the Pressure Gauge on
the Flow Meter. (Best Method since Flow Meter will usually be installed.)

If Pressure does not Match Work Tool Program for Electronic Reliefs, Perform the Line
Relief Calibration.

Pump Pressures read on

the Monitor are usually Close Return Ball Valve
200 psi greater than the or
actual pressure at the Close Flow Meter
Work Tool
Calibrations – Flow

Flow @ Pressure
Set Flow @ Pressure
Horsepower = Flow @ Pressure
Example: H160DS = 75 gpm @ 2300 psi

Operating Pressure Note:

Temp GPM
If Flow @ Pressure is different from Cat
ET / Monitor and End of Stick,
Calibration MUST be performed

Auxiliary Flow @ Pressure

Calibrations – Flow

Un-Check the PRV –

Pressure Gauge Box
This calibration is
performed at the factory
and is not used with a flow
meter
Calibrations – Flow

Follow
Steps for
Calibration

Use slide bar and flow meter

to maintain correct flow at
recommended pressure
Calibrations – Flow

Verify Flow and Pressure Data

Set Flow @ Pressure

Horsepower = Flow @ Pressure Verify Results by running a
Example: H160DS = 75 gpm @ 2300 psi Hammer Tool Program at
2300 psi.
Operating Pressure

Temp GPM If Flow is more than + or – 1

GPM, perform Flow
Calibration a second time.

Auxiliary Flow @ Pressure

Monitor

C Series Monitor

Possible Tool Selections

D & E Series Monitor

Possible Tool Selections

Monitor

What Happens “IF” Wrong Selection is Made?

105

100

95 Aux - 10
Aux - 9
90

85 Aux - 8
80 Aux - 7
75 Aux - 6
70
Aux - 5
65

60
Aux - 4
Flow (gpm)

55 Aux - 3
50

45 Aux - 2
40

35
Aux - 1
30

25

20

15

10
D & E Series Monitor
5

0
1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 4000
Pressure (psi)
Monitor

Best Practice – Set Only Work Tools that are Needed

105 100

100 95

95 90 Aux - Aux
10 – 2 …Shear Application
Aux - 9
90 85

85 80 Aux - 8
80 75 Aux - 7
75
70 Aux - 6
70
65 Aux - 5
65
60
60
Aux - 4
55 Aux – 1…..H130S Application
Flow (gpm)
Flow (gpm)

55 Aux - 3
50
50
45
Aux - 2
 Set Non-used Modes to Zero gpm
45
40
40
35
35
Aux - 1
30

25
30

25
 Eliminate Possible Problems from Selection Process
20
20

15 15

10 10

5 5

0 0
10001000 12001200 14001400 16001600 18001800 20002000 22002200 24002400 26002600 28002800 30003000 32003200 34003400 36003600 38003800 40004000
Pressure
Pressure (psi)(psi)
Monitor

Eliminate Problems, use Correct Selection

140

120
Incorrect Mode

100

80
Over
flow
60 H140DS mode
H140DS 60 gpm
Flow range
40
42 gpm

20

0 500 1000 1500 2000 2500 3000

Current Totals ET

Check Current Totals to get

Button Hours for each Tool
Program
Work Tool Issues

Potential Areas for a Work Tool Problem:

1. Carrier System Eliminate two of the three possible problems

Electrical 1) Eliminate the Carrier as a problem
Relief setting
2) Eliminate the Hydraulic Kit as a problem
Flow setting
Filter

2. Hydraulic Kit
Quick coupler failure
Damaged or pinched hose
Ball valve closed

3. Work Tool
Carrier and Work Tool Inspection

Inspect
 Auxiliary Circuit (Restrictions or Small Lines)
 Ball valves fully opened
 Damaged hoses
 Missing or loose bolts

1
Test
 Relief valve setting
 Operating pressure set correctly
Record
 Service Meter Hours (smu)
 Work Tool Auxiliary Hours
 Is Correct Tool Selected
4  Take a Product Status Report
Inspect
 Grease fittings (Missing or Worn)?
 Adequate amount of Grease seen on Work Tool? 2
 Work Tool Wear Part Condition?
 General Work Tool Condition?
 Correct Grease Used? Verify
 Auto-lube function correctly
Observe  Grease canister is full
 Correct Operating Practices  Correct grease is being used
Carrier Setup

Questions?