Converting AHC to Manual Foot Controls in Excavators

[MikePhua]

Advanced Hand Controls (AHC) systems in excavators offer precision and ease of operation, but they can present challenges when they malfunction or become difficult to repair. For operators seeking a more straightforward and reliable control system, converting from AHC to manual foot controls is a viable solution. This conversion not only simplifies the control mechanism but also enhances durability and reduces maintenance complexities.
Understanding AHC Systems
AHC systems utilize electronic actuators and sensors to control hydraulic valves, allowing for precise movements of the excavator's boom, stick, and bucket. While these systems offer smooth operation, they are susceptible to issues such as electrical failures, sensor malfunctions, and actuator wear. These problems can lead to inconsistent performance and costly repairs.
Benefits of Manual Foot Controls
Converting to manual foot controls offers several advantages:

• Simplicity: Mechanical linkages are less prone to electronic failures.
  
• Cost-Effectiveness: Reduced need for expensive electronic components and sensors.
  
• Durability: Foot pedals and mechanical linkages are robust and can withstand harsh operating conditions.
  
• Ease of Maintenance: Mechanical systems are easier to troubleshoot and repair.
  

Conversion Process
The conversion involves several key steps:

1. Remove AHC Components: Disconnect and remove the electronic actuators, sensors, and associated wiring from the excavator's control system.
   
2. Install Mechanical Linkages: Install mechanical linkages that connect the foot pedals to the hydraulic control valves. These linkages should be designed to provide the necessary range of motion and force transmission.
   
3. Mount Foot Pedals: Position the foot pedals in a location that allows for comfortable operation. Ensure that the pedals are securely mounted and that they do not interfere with other controls or components.
   
4. Adjust Hydraulic Valves: Modify the hydraulic control valves to accept mechanical input from the foot pedals. This may involve replacing electronic actuators with manual control spools or adding mechanical detents.
   
5. Test the System: After installation, thoroughly test the system to ensure that all movements are responsive and that there are no hydraulic leaks or binding in the linkages.
   

Considerations and Challenges
While converting to manual foot controls can be beneficial, there are several considerations:

• Control Pattern: Ensure that the manual controls follow the desired control pattern (e.g., ISO or SAE) to maintain operator familiarity.
  
• Hydraulic Compatibility: Verify that the existing hydraulic system can accommodate the manual controls without compromising performance.
  
• Operator Training: Operators may need training to adapt to the new control system, especially if they are accustomed to AHC systems.
  

Real-World Applications
Many operators have successfully converted their excavators from AHC to manual foot controls. For instance, a Bobcat 753 F-series owner reported intermittent issues with the AHC system, including unresponsive controls and error codes. After troubleshooting and considering the cost of repairs, they explored the possibility of converting to manual foot controls but found the process complex and costly without a clear parts list.
Conclusion
Converting an excavator from AHC to manual foot controls is a practical solution for operators seeking reliability and ease of maintenance. While the conversion process requires careful planning and execution, the benefits of increased durability and reduced electronic dependency make it a worthwhile consideration for many. Operators should assess their specific needs, available resources, and technical expertise before undertaking such a conversion.