CNH Breaker circuit pedal kit CX160D Crawler excavator Installation Instructions Manual 47900369

INSTALLATION INSTRUCTIONS

KG0LP416-00

BREAKER CIRCUIT PEDAL KIT

APPROXIMATE INSTALLATION TIME: 28.0 hours

San - 47900369 Issue date July 2015 EN

KG0LP416-00 - BREAKER CIRCUIT PEDAL KIT CASE CONSTRUCTION CX160D

San - 47900369 Issue date July 2015 EN

Contents 1 KIT CONTENT Kit content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2 PRE-ASSEMBLY PREPARING FOR ASSEMBLY Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

3 ASSEMBLY BREAKER CIRCUIT PEDAL KIT Boom line installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Upper main line installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Service valve (remote control valve) installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Service valve (remote control valve) pilot line installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Service valve (remote control valve) harness installation . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Tank indicator sensor installation (filter clog warning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Additional processing for the floor mat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Installation of nameplate inside cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

EN

EN

1 - KIT CONTENT

1 - KIT CONTENT Kit content NOTE: Please refer to the Parts Manual for parts orders.

Service valve (Refer to 3-10) Item 4 5 6 7 8 9 10 11 12 14 15 16 17 18 19 20 21

Description Remote control valve Sems bolt M10x25 Option right pedal bracket Option pedal bracket Hexagon socket head bolt High-strength washer M10 Option pedal Hexagon socket head bolt M10x30 High-strength washer M10 Lock bracket Hexagon socket head bolt M10x16 High-strength washer M10 Lock lever Compression spring High-strength nut M8 Plain washer M8 Pedal plastic cover

Quantity 1 2 1 1 2 2 1 2 2 1 2 2 1 1 1 1 1

Part Reference KHJ24720 105R010Y025R KHJ24740 KHJ24780 KHJ1104 KHJ0183 KHJ13850 KHJ24800 KHJ0183 KHJ10711 108R010Y016R KHJ0183 KHJ10701 KHJ10721 KHJ0091 KHN0420 KHP0912

Quantity 2 5 3 1 1 12 1 2 1 1 1 2 4 1 1 1

Part Reference KLJ11690 KHJ1360 KHJ1941 KLJ14020 KNJ2732 105R012Y030R KRJ16050 KRJ12170 KAJ2434 KLJ14860 KNJ0605 KRJ2681 108R010Y030R KHJ0913 KRJ11470 KHH0142

Quantity 2 2 1 1 2 2

Part Reference KNJ0758 KHJ0363 KLJ14930 CNA0584 KHJ28580 KHJ28810

Breaker main circuit (Refer to 3-5) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Description Hydraulic hose O-ring Hose adapter Hydraulic hose Port relief valve Sems bolt M12x30 Bracket Manifold Hose adapter G1 x G3/4 Hydraulic hose Hose adapter G3/4 Split flange Hexagon socket head bolt M10x30 O-ring Bracket Wire band L = 250

Breaker pilot circuit (Refer to 3-12) Item 1 2 3 4 5 6

Description Hose adapter G1/4 Plug G1/4 Assembly hose Nipple with filter G1/4 Elbow G1/4 Long elbow

1-1 EN

1 - KIT CONTENT

Item 7 8 9 10 11 12 13 14 15 16

Description Stud G1/4 Assembly hose Tee G1/4 Wire band L = 250 Mount clamp Phillips pan head screw M6x8 Pressure sensor Wire band L = 380 Wire band L = 300 Clamp with band M8

Quantity 1 1 1 – 4 4 1 – – 1

Part Reference KHJ13640 KLJ15010 KHJ2773 KHH0142 KHR0319 145N006S008R KHR26940 KAR0017 KHH0143 KHR2581

Quantity 1 3 3 3

Part Reference KHR39480 KHH0142 KHR1957 KHR1253

Quantity 1 1 2

Part Reference KHR32870 KHR33420 KHH0142

Quantity 1

Part Reference KHP27010

Quantity 2 4 8

Part Reference KHV10990 KHV10460 KHV10450

Quantity 2 1 1 2 1 1 6

Part Reference KHJ1898 KLV12390 KLV12380 BRJ1286 KLV13710 KLV13700 KHJ1360

Electrical part (Refer to 3-17) Item 93 94 95 96

Description Option (pedal) wire harness Wire band L = 250 Clip Bolt M6x16

Indicator (Refer to 3-20) Item 1 2 3

Description Pressure sensor G1/4 Sensor wire harness Wire band L = 250

Plate (Refer to 3-22) Item 91

Description Foot control operation label ( ISO)

Clamp (Refer to 3-1) Item 1 2 3

Description Pipe clamp Pipe clamp Pipe clamp

Line (Refer to 3-1) Item 4 5 6 7 8 9 10

Description Plug G1/4 Line assembly Line assembly Plug G3/4 Line assembly Line assembly O-ring

(right–hand) (left–hand) (right–hand) (left–hand)

1-2 EN

2 - PRE-ASSEMBLY

2 - PRE-ASSEMBLY PREPARING FOR ASSEMBLY

Preparation An “*” in this document indicates that the part is mounted on the actual machine.

Items to prepare: • Wrenches ( 10 mm, 13 mm, 17 mm, 19 mm, 36 mm, 41 mm) • Box wrenches ( 10 mm, 13 mm, 17 mm, 19 mm, 41 mm) • Hexagon wrenches ( 8 mm) • Phillips screwdriver (No. 3) • Cutters, scissors • Rag 1. Position the main unit.

• Put the main unit on solid, level ground, put the bucket cylinder at its open stroke end, the arm cylinder at its open stroke end, lower the boom, and touch the arm top to the ground.

SMIL13II00106AA

1

SMIL13II00107AA

2

2. Switch the ignition key (a) “OFF”, check that the engine has stopped, and then switch the ignition key “ON” again. (Do not start the engine.)

2-1 EN

2 - PRE-ASSEMBLY

3. Bleed out the pressure inside the circuit.

• Flip the lever (c) forward, and then turn the upper operation lever (b) about 10 times to bleed out the pressure.

• Move the travel lever (d) back and forth about 5 times to bleed out the pressure.

SMIL13II00108BA

3

SMIL13II00109AA

4

4. Bleed out the pressure from inside the hydraulic tank.

• Press the air breather button (e) on top of the hydraulic tank to release the pressure inside the tank.

2-2 EN

3 - ASSEMBLY

3 - ASSEMBLY BREAKER CIRCUIT PEDAL KIT

Boom line installation

SMIL15CEX8917FB

1

Line Assemblies (8) (9) 1. Set the line assembly (left) (9) on the boom.

SMIL15CEX8918AB

2

3-1 EN

3 - ASSEMBLY

2. Sandwich the line assembly (left) (9) at two locations with two pipe clamps (3) each, and then fasten with two sems bolts (*1) each.

• Fasten one of the pipe clamps (3) at a position 288 mm (11.339 in) from the rear end of the line assembly (left) (9).

SMIL15CEX8919AB

3

SMIL15CEX8920AB

4

SMIL15CEX8921BB

5

3. Set the O-ring (10) on the line assembly (left) (9), and then install the plug (7).

4. Sandwich the line assembly (left) (9) with two pipe clamps (2), and then fasten with two sems bolts (*1).

• Fasten the pipe clamps (2) at a position 205 mm (8.071 in) from the front end of the line assembly (left) (9).

5. Install the line assembly (right) (8) in the same way as the line assembly (left) (9).

3-2 EN

3 - ASSEMBLY

Line Assemblies (5) (6) 1. Set the line assembly (left) (6).

SMIL15CEX8922BB

6

SMIL15CEX8923AB

7

SMIL15CEX8924AB

8

2. Fasten the line assembly (left) (6) with one pipe clamp (1) and two sems bolts (*1).

• Fasten the pipe clamp (1) at a position 127 mm (5.000 in) from the front end of the line assembly (left) (6).

3. Set the O-ring (10) on the rear end of the line assembly (left) (6), and then connect to the line assembly (left) (9).

3-3 EN

3 - ASSEMBLY

4. Set the O-ring (10) on the front end of the line assembly (left) (6), and then install the plug (4).

SMIL15CEX8925AB

9

5. Install the line assembly (right) (5) in the same way as the line assembly (left) (6).

3-4 EN

3 - ASSEMBLY

Upper main line installation

SMIL15CEX8965GB

1

3-5 EN

3 - ASSEMBLY

Upper Main Line Installation (left side) 1. Install the bracket (15) on the frame with four sems bolts (6).

Install the manifold (8) on the bracket (15) with two sems bolts (6).

SMIL15CEX8926BB

2

SMIL15CEX8927BB

3

2. Install the hose adapter (3) on the manifold (8).

Set the O-ring (2) on the manifold (8) and connect the hydraulic hose (1).

• Tightening torque: 142.349 lb ft)

157 - 193 N·m (115.797 -

3-6 EN

3 - ASSEMBLY

3. Set the O-ring (2) on the line (*3) and connect the hydraulic hose (1).

• 157 - 193 N·m (115.797 - 142.349 lb ft)

SMIL15CEX8928AB

4

SMIL15CEX8929AB

5

SMIL15CEX8930BB

6

4. Install the hose adapter (3) on the manifold (8).

Set the O-ring (2) on the manifold (8) and connect the hydraulic hose (10).

• 157 - 193 N·m (115.797 - 142.349 lb ft)

5. Set the O-ring (14) on the control valve (*1) 5B4 port, and install the hydraulic hose (10) with two split flanges (12) and four hexagon socket head bolts (13).

3-7 EN

3 - ASSEMBLY

Upper Main Line Installation (right side) 1. Install the bracket (7) on the frame with four sems bolts (6).

SMIL15CEX8931AB

7

SMIL15CEX8932BB

8

SMIL15CEX8933AB

9

2. Install the manifold (8) on the bracket (7) with two sems bolts (6).

Install the hose adapter (3) on the manifold (8).

Set the O-ring (2) on the hose adapter (3) and connect the hydraulic hose (1).

• 157 - 193 N·m (115.797 - 142.349 lb ft)

3. Set the O-ring (2) on the hydraulic hose (1) and connect to the line assembly (*4).

• 157 - 193 N·m (115.797 - 142.349 lb ft)

3-8 EN

3 - ASSEMBLY

4. Install the hose adapter (9) on the manifold (8).

Connect the hydraulic hose (4) to the hose adapter (9).

SMIL15CEX8934AB

10

SMIL15CEX8935AB

11

SMIL15CEX8936BB

12

5. Install the hose adapter (11) on the hydraulic tank (*2).

Connect the hydraulic hose (4) to the hose adapter (11) and fasten with the wire band (16).

• Connect the hydraulic hose (4) with the horizontal angle of 45° down.

Port Relief Valve Installation 1. Remove the plug, then install the port relief valves (5) on the control valve (*1).

• 78.4 - 88.3 N·m (57.825 - 65.127 lb ft) After installing the port relief valves (5), adjust the relief pressure to match the attachment used. (See the Service Manual.)

A. Left

3-9 EN

3 - ASSEMBLY

Service valve (remote control valve) installation

SMIL14II01007FA

1

1. Remove the floor mat from the cab.

2. Install the remote control valve (4) on the front right section of the floor with 2 sems bolts (5).

Install the option right pedal bracket (6) on the remote control valve (4) with 2 hexagon socket head bolts (8) and 2 high-strength washers (9).

SMIL14II01008AB

2

3-10 EN

3 - ASSEMBLY

3. Set the lock lever (17) and the compression spring (18) on the lock bracket (14), then fasten with the highstrength nut (19) and plain washer (20).

Fit the lock lever (17) onto the slot of the option right pedal bracket (6), then install the lock bracket (14) on the floor with the 2 hexagon socket head bolts (15) and 2 high-strength washers (16).

SMIL14II01009BB

3

SMIL14II01010AB

4

4. Install the option pedal bracket (7) and option pedal (10) with 2 hexagon socket head bolts (11) and 2 highstrength washers (12).

Cover the option pedal (10) with the pedal plastic cover (21).

3-11 EN

3 - ASSEMBLY

Service valve (remote control valve) pilot line installation

SMIL15CEX8937FB

1

SMIL15CEX8938FB

2

3-12 EN

3 - ASSEMBLY

SMIL15CEX8939FB

a. Assembly hose b. Code c. Pedal front operation d. Pedal rear operation e. Pressure f. Return

*1. *2. *3. *4. *5.

3

Remote control valve Manifold Control valve Hydraulic tank Return line

1. Install the hose adapter (1) on the remote control valve (*1) T port.

SMIL15CEX8940AB

4

3-13 EN

3 - ASSEMBLY

2. Install the elbow (5) on the manifold (*2) T5 port.

Connect the remote control valve (*1) T port and manifold (*2) T5 port with the assembly hose (3) (T5).

SMIL15CEX8941AB

5

SMIL15CEX8942AB

6

SMIL15CEX8943AB

7

SMIL15CEX8944AB

8

3. Install the plug (2) on the remote control valve (*1) C1 port.

Install the nipple with filter (4) on the remote control valve (*1) P port.

4. Install the elbow (5) on the manifold (*2) P5 port.

Connect the remote control valve (*1) P port and manifold (*2) P5 port with the assembly hose (3) (P5).

5. Install the plug (2) on the remote control valve (*1) A port.

Install the hose adapter (1) on the remote control valve (*1) B port.

Install the pressure switch (13) on the remote control valve (*1) C2 port.

3-14 EN

3 - ASSEMBLY

6. Install the long elbow (6) on the control valve (*3) 5b4 port.

Connect the remote control valve (*1) B port and control valve (*3) 5b4 port with the assembly hose (3) (Y1).

• Install the long elbow (6) with the horizontal angle of 80° down.

A. Left

SMIL15CEX8945AB

9

7. Remove the pilot P and T lines and elbow (*6) from the return line (*5).

Install the tee (9) on the return line (*5), and then connect the elbow (*6) and pilot P and T lines.

A. Left

SMIL15CEX8946AB

10

SMIL15CEX8947AB

11

8. Install the stud (7) and long elbow (6) on the control valve (*3) 5a4 port.

Connect the long elbow (6) and the return line (*5) elbow (*6) with the assembly hose (8) (Y2) and fasten with three wire bands (10).

• Fasten the assembly hose together with the pilot control line (*7).

3-15 EN

3 - ASSEMBLY

9. Fasten the assembly hose that comes out from the remote control valve (*1) at four locations with one mount clamp (11) each, one Phillips pan head screw (12) each, and one wire band (10) each.

Fasten the assembly hose that comes out from the remote control valve (*1) with four wire bands (15).

• Fasten the assembly hose together with the pilot control line (*7).

SMIL15CEX8948BB

12

SMIL15CEX8949AB

13

SMIL15CEX8950AB

14

10. Fasten the assembly hose (3) (Y1) with the clamp with band (16) and three wire bands (14).

• Fasten the assembly hose (3) (Y1) together with the pilot P and T lines and pilot control line.

11. Fasten the assembly hose (3) (Y1) with the wire band (10).

• Fasten the assembly hose (3) (Y1) together with the pilot P and T lines and pilot control line.

3-16 EN

3 - ASSEMBLY

Service valve (remote control valve) harness installation

SMIL14II01022FB

1

SMIL14II01023FB

2

3-17 EN

3 - ASSEMBLY

1. Fasten the wire harness (93) and remote control valve (*1) and fasten with the wire band (94).

SMIL14II01024AB

3

SMIL14II01025AB

4

SMIL14II01026AB

5

SMIL14II01027AB

6

2. Route the wire harness (93) as shown in the diagram.

Fasten the wire harness (93) at 6 locations with 6 wire bands (*2).

3. Fasten the 3 couplers on the wire harness (93) with 1 clip (95) each and 1 bolt (96) each.

4. Connect the wire harness (93) connector (8-pin) to the frame main harness (*3) and fasten with the wire band (94).

3-18 EN

3 - ASSEMBLY

5. Extend the wire harness (93) to the floor side from under the cab.

Connect the wire harness (93) connector (16-pin) to the cab main harness and fasten with the wire band (94).

SMIL14II01028AB

7

3-19 EN

3 - ASSEMBLY

Tank indicator sensor installation (filter clog warning)

SMIL15CEX8951FB

1

1. Install the pressure sensor (1) on the hydraulic tank (*1) tee (*2).

Connect the sensor wire harness (2) to the pressure sensor (1).

SMIL15CEX8952AB

2

SMIL15CEX8953AB

3

2. Connect the sensor wire harness (2) to the frame main wire harness (*3) and fasten with three wire bands (3).

• Fasten two of the three wire bands (3) together with the breaker circuit main line (*4).

3-20 EN

3 - ASSEMBLY

Additional processing for the floor mat

SMIL15CEX8954GB

1

1. Remove the floor mat from the cab.

2. Spread out the floor mat on a flat platform and mark the dimensional positions.

3. Use cutters or scissors to cut slits (*1).

4. Set the cut floor mat in the cab.

3-21 EN

3 - ASSEMBLY

Installation of nameplate inside cab

SMIL15CEX8955GB

1

1. Wipe off any dirt from the location where the label will be attached.

2. Attach the foot control operation label (ISO) (91).

3-22 EN

Index ###_Index_###

A Additional processing for the floor mat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 B Boom line installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1

I Installation of nameplate inside cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 K Kit content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

P Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

S Service valve (remote control valve) harness installation . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Service valve (remote control valve) installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Service valve (remote control valve) pilot line installation . . . . . . . . . . . . . . . . . . . . . . . . 3-12 T Tank indicator sensor installation (filter clog warning) . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 U Upper main line installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5

EN

SERVICE - Technical Publications & Tools

© 2015 CNH Industrial Italia S.p.A. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

CNH policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved.

All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your CNH Dealer.

CNH Industrial Italia S.p.A. viale delle Nazioni, 55 Modena Italy 41122 EN