CNH Breaker Circuit Proportional Control Kit CX300D Installation Instructions Manual 47789439 - PDF

INSTALLATION INSTRUCTIONS

KG1BP512-00

BREAKER CIRCUIT PROPORTIONAL CONTROL KIT

APPROXIMATE INSTALLATION TIME: 28.0 hours

San - 47789439 Issue date January 2015 EN

KG1BP512-00 - BREAKER CIRCUIT PROPORTIONAL CONTROL KIT CASE CONSTRUCTION CX300D

San - 47789439 Issue date January 2015 EN

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

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

3 ASSEMBLY BREAKER CIRCUIT PROPORTIONAL CONTROL KIT Boom line installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Upper main line installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Pilot line installation - proportional control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Harness installation - Proportional control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Control lever installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Tank indicator sensor installation (filter clog warning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Installation of nameplate inside cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

EN

EN

1 - KIT CONTENT

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

Control lever (right) (Refer to 3-21) Item 1

Description Knob (right) proportional control

Quantity 1

Part Reference KHJ28550

Quantity 1 1 2 4 3 1 1 1 12 2 2 2 4 8 1 1 1 2 1 1 1 1

Part Reference KBJ23800 KHJ0914 KRJ2682 108R010Y030R KHJ1361 KHJ11370 KHJ15050 KRJ11470 105R012Y030R KHJ1349 KBJ11790 M20J0771 KTJ0029 108R014Y050R KHJ25900 KRJ16400 KBJ16300 KHJ0351 KBJ13790 KHJ0352 KBJ19800 KHJ0345

Quantity 1 2 1 2 2 1 1 1 1 2 1 1 2 4 4 4

Part reference MFJ71500 105R008Y016R KHJ28770 105R010Y020R KNJ0758 CNA0584 KAJ3807 KHJ0363 KBJ23840 KHJ28690 KBJ23820 KHR26940 KHJ28580 KHR0319 145N006S008R KHH0142

Breaker main circuit (Refer to 3-5) Item 4 5 6 7 8 9 10 11 12 13 15 16 17 18 21 22 23 26 27 29 30 31

Description Hydraulic hose O-ring Split flange ( G1) Hexagon socket head bolt ( M10 x 30) O-ring Elbow Relief valve Bracket Sems bolt ( M12 x 30) Hose adapter Hydraulic hose O-ring Split flange ( G1 x 1/4) Hexagon socket head bolt ( M14 x 50) Socket Manifold Bracket Elbow ( G3/4) Hydraulic hose Elbow ( G1) Hydraulic hose Elbow ( G1)

Breaker pilot circuit, proportional control (Refer to 3-12) Item 34 35 36 37 38 39 40 41 42 44 45 48 50 51 52 53

Description Reducing valve Sems bolt ( M8 x 16) Bracket Sems bolt ( M10 x 20) Hose adapter ( G1/4) Nipple with filter ( G1/4) Tee ( G1/4) Plug ( G1/4) Assembly hose Elbow Assembly hose Pressure sensor Elbow ( G1/4) Mount clamp Phillips pan head screw ( M6 x 8) Wire band (L = 250)

1-1 EN

1 - KIT CONTENT

Electrical part (Refer to 3-17) Item 81 82 83 84

Description Option (proportional control) wire harness Wire band (L = 250) Clip Bolt ( M6 x 16)

Quantity 1 2 3 3

Part reference KHR39500 KHH0142 KHR1957 KHR1253

Quantity 1 1 1 2 2

Part reference KHJ12530 KHR32870 KHR33580 KHR2584 KHJ1215

Quantity 1

Part reference KHP27030

Quantity 8 4 2 4

Part Reference KHV11050 KHV11060 KHV11070 105R012Y030R

Quantity 1 1 2 4 8 2 1 1

Part Reference KBV32410 KBV18900 M20J0771 KTJ0029 108R014Y050R BRJ1286 KBV32420 KBV18910

Quantity 2 2 8

Part Reference KUP0009 M20J0771 108R014Y050R

Indicator (Refer to 3-25) Item 56 57 58 59 60

Description Tee ( G1/4 x G3/8) Pressure sensor ( G1/4) Sensor wire harness Clamp with band ( M8) Special bolt ( M8 x 25)

Plate (Refer to 3-27) Item 75

Description Operation label (proportional control)

Clamp (Refer to 3-1) Item 78 79 80 81

Description Pipe clamp Pipe clamp Pipe clamp Sems bolt ( M12 x 30)

Line (Refer to 3-1) Item 83 84 85 86 87 88 89 90

Description Line assembly (left) Line assembly (left) O-ring Split flange ( G1 x 1/4) Hexagon socket head bolt ( M14 x 50) Plug ( G3/4) Line assembly (right) Line assembly (right)

Plug (Refer to 3-1) Item 97 98 99

Description Flat flange O-ring Hexagon socket head bolt ( M14 x 50)

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 ( 13 mm, 17 mm, 19 mm, 36 mm, 41 mm, 46 mm, 50 mm) • Hexagon wrenches ( 8 mm, 12 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 PROPORTIONAL CONTROL KIT

Boom line installation

SMIL14CEX5781FB

1

3-1 EN

3 - ASSEMBLY

Line assemblies (84) and (90) 1. Set the line assembly (left) (84) on the boom.

SMIL14CEX5782BB

2

SMIL14CEX5783AB

3

SMIL14CEX5784AB

4

2. Sandwich the line assembly (left) (84) at 2 locations with 2 pipe clamps (78) each, and then fasten with 2 sems bolts (*1) each.

• Fasten the rear pipe clamp (78) at a position 287 mm from the rear end of the line assembly (left) (84).

3. Install the plug (88) on the line assembly (left) (84).

4. Install the line assembly (right) (90) in the same way as line assembly (left) (84).

3-2 EN

3 - ASSEMBLY

Line assemblies (83) and (89) 1. Set the line assembly (left) (83).

SMIL14CEX5785AB

5

SMIL14CEX5786AB

6

SMIL14CEX5787AB

7

SMIL14CEX5788AB

8

2. Fasten the line assembly (left) (83) with 1 pipe clamp (80) and 2 sems bolts (*1).

• Fasten the pipe clamp (80) at a position 130 mm from the front end of the line assembly (left) (83).

3. Set the O-ring (85) on the end of the line assembly (left) (83), and then connect the line assembly (left) (83) with the 2 split flanges (86) and the 4 hexagon socket head bolts (87).

4. Fasten the line assembly (left) (83) with 2 pipe clamp (79) and 81 sems bolt (2).

3-3 EN

3 - ASSEMBLY

5. Set the O-ring (98) on the front end of the line assembly (left) (83) , and then install the flat flange (97) with 4 hexagon socket head bolts (99).

SMIL14CEX5789AB

9

6. Install the line assembly (right) (89) in the same way as the line assembly (left) (83).

• Fasten the pipe clamp (89) at a position 305 mm from the front end of the line assembly (right) (100).

3-4 EN

3 - ASSEMBLY

Upper main line installation

SMIL14CEX5790GB

1

3-5 EN

3 - ASSEMBLY

Upper main line installation (left side) 1. Install the bracket (11) on the frame with 4 sems bolts (12).

Install the relief valve (10) on the bracket (11) with the 2 sems bolts (12).

• Adjust the set pressure for the relief valve (10) to match the type of attachment used.

SMIL14CEX5791BB

2

SMIL14CEX5792BB

3

2. Install the elbow (9) on the relief valve (10) A port.

Set the O-ring (8) on the elbow (9) and connect the hydraulic hose (4).

Set the O-ring (8) on the hose adapter (9) and connect the hydraulic hose (17).

3-6 EN

3 - ASSEMBLY

3. Set the O-ring (5) on the control valve (*1) A2 port, and install the hydraulic hose (4) with 2 split flanges (6) and 4 hexagon socket head bolts (7).

SMIL14CEX5793BB

4

SMIL14CEX5794BB

5

4. Install the hose adapter (13) on the relief valve (10) B port. Set the O-ring (8) on the hose adapter (13) and install the hydraulic hose (15).

3-7 EN

3 - ASSEMBLY

5. Set the O-ring (16) on the hydraulic hose (15), and then connect to the line assembly (left) (*3) with 2 split flanges (17) and 4 hexagon socket head bolts (18).

SMIL14CEX5795BB

6

SMIL14CEX5797AB

7

Upper main line installation (right side) 1. Install the bracket (23) on the frame with 4 sems bolts (12).

3-8 EN

3 - ASSEMBLY

2. Install the manifold (22) on the bracket (23) with 2 sems bolts (12).

SMIL14CEX5796BB

8

SMIL14CEX5798AB

9

3. Install the elbow (29) on the manifold (22) hydraulic tank (*2) side. Connect the hydraulic hose (30) to the elbow (29).

3-9 EN

3 - ASSEMBLY

4. Install the elbow (31) on the hydraulic tank (*2). Connect the hydraulic hose (30) to the elbow (31).

SMIL14CEX5799BB

10

SMIL14CEX5800BB

11

5. Install the elbow (26) on the relief valve (10) T port.

Install the elbow (26) on the manifold (22) relief valve side.

Connect the relief valve (10) T port and manifold (22) relief valve side with the hydraulic hose (27).

3-10 EN

3 - ASSEMBLY

6. Install the socket (21) on the manifold (22) line assembly (right) (*4) side to connect the hose adapter (13).

Set the O-ring (8) on the hose adapter (13) and connect the hydraulic hose (15).

SMIL14CEX5801AB

12

SMIL14CEX5802BB

13

7. Set the O-ring (16) on the hydraulic hose (15), and then connect to the line assembly (*4) with 2 split flanges (17) and 4 hexagon socket head bolts (18).

Install the hose adapter (29) on the manifold (25) relief valve (11) side. Connect the relief valve (11) T port and manifold (25) relief valve (11) side with the hydraulic hose (30).

3-11 EN

3 - ASSEMBLY

Pilot line installation - proportional control

SMIL14CEX5803FB

SMIL14II01063FB

1

2

3-12 EN

3 - ASSEMBLY

SMIL14CEX5804FB

a. b. *1.

Hose assembly Code Floor

*2. *3. *4.

3

Manifold Control valve Hydraulic tank

3-13 EN

3 - ASSEMBLY

1. Install the reducing valve (34) on the bracket (36) with 2 sems bolts (35) .

2. Install the bracket (36) on the floor (*1) with 2 sems bolts (37).

SMIL14CEX5805AB

4

SMIL14CEX5806AB

5

SMIL14CEX5807AB

6

SMIL14CEX5808AB

7

3. Install the hose adapter (38) on the reducing valve (34) T port.

4. Install the elbow (50) on the manifold (*2) T5 port. Connect the reducing valve (34) T port and manifold (*2) T5 port with the assembly hose (42/T5).

5. Install the nipple with filter (39) on the reducing valve (34) P port.

3-14 EN

3 - ASSEMBLY

6. Install the elbow (50) on the manifold (*2) P5 port. Connect the reducing valve (34) P port and manifold (*2) P5 port with the assembly hose (42/P5).

SMIL14CEX5809AB

8

SMIL14CEX5810AB

9

7. Install the plug (41) on the reducing valve (34) A1 port.

Install the tee (40) on the reducing valve (34) A2 port.

8. Install the elbow (44) on the control valve (*3) pa2 port.

Connect the reducing valve (34) A2 port and control valve (*3) pa2 port with the assembly hose (42/Y1).

SMIL14CEX5811BB

10

3-15 EN

3 - ASSEMBLY

9. Install the elbow (44) on the control valve (*3) pb2 port.

Install the hose adapter (38) on the hydraulic tank (*4).

Connect the control valve (*3) pb2 port and the hydraulic tank (*4) with the assembly hose (45/Y2).

• Fasten the assembly hose (45/Y2) together with the pilot control line.

SMIL14CEX5812BB

11

SMIL14CEX5813AB

12

10. Fasten the assembly hoses (42/Y1) (42/P5) (42/T5) that come out from the reducing valve (34) at 4 locations with 1 mount clamp (51) each, 1 Phillips pan head screw (52) each, and 1 wire band (53) each.

Install the pressure sensor (48) on the reducing valve (34).

3-16 EN

3 - ASSEMBLY

Harness installation - Proportional control

SMIL14II01074FB

1

SMIL14II01075FB

2

3-17 EN

3 - ASSEMBLY

1. Connect the wire harness (81) and the reducing valve (*1).

SMIL14II01076BB

3

SMIL14II01077BB

4

2. Route the wire harness (81) as shown in the diagram.

Fasten the wire harness (81) at 6 locations with 6 wire bands (*2).

3-18 EN

3 - ASSEMBLY

3. Fasten the 3 couplers on the wire harness (81) with 1 clip (83) each and 1 bolt (84) each.

SMIL14II01078BB

5

SMIL14II01079BB

6

4. Connect the wire harness (81) connector (8-pin) to the frame main harness (*3) and fasten with the wire band (82)

3-19 EN

3 - ASSEMBLY

5. Extend the wire harness (81) to the floor side from under the cab.

Connect the wire harness (81) connector (16-pin) to the cab main harness and fasten with the wire band (82).

SMIL14II01080BB

7

3-20 EN

3 - ASSEMBLY

Control lever installation Removal of control lever (right) 1. Roll up the boot (*1) of the control lever and use the Phillips screwdriver or box wrench 10 mm to remove the 2 bolts (*2) of the console top cover.

SMIL14II00167AB

1

SMIL14II00168AB

2

SMIL14II00169AB

3

SMIL14II00170AB

4

2. Use the Phillips screwdriver to remove the 2 screws (*3), and then remove the handle of the tilt lever (*4).

3. Use the Phillips screwdriver to remove the 2 screws (*5) of the console top cover.

4. Remove the connectors (*6) and remove the console top cover (*7).

3-21 EN

3 - ASSEMBLY

5. Use a Phillips screwdriver or box wrench 10 mm to remove the 5 bolts (*8) and remove the cover (*9).

SMIL14II00175AB

5

SMIL14II00171AB

6

SMIL14II00172AB

7

SMIL14II00173AB

8

6. Roll up the boot (*10) of the control lever, remove the connector (*11) of the lever switch, and cut the wire band (*12).

7. While fastening the nut (*13) with a wrench 22 mm, use a wrench 19 mm to remove the lock nut (*14) and remove the control lever (*15).

Installation of control lever (right) 1. After installing the knob (right) (1), while fastening the nut (*13) with a wrench 22 mm, use a wrench 19 mm to install the lock nut (*14).

Lock nut tightening torque: 38.3 - 44.1 N·m (28.25 32.53 lb ft)

3-22 EN

3 - ASSEMBLY

2. Install the horn switch connector (*11), bundle with the wire band (*12), and then cover the control lever boot (*10).

SMIL14II00174AB

9

3. Use a Phillips screwdriver or box wrench 10 mm to install the cover (*9) with 5 bolts (*8).

SMIL14II00175AB

10

SMIL14II00176AB

11

SMIL14II00177AB

12

4. Install the connectors (*6) and install the console top cover (*7).

5. Use the Phillips screwdriver to install the 2 screws (*5) of the console top cover.

3-23 EN

3 - ASSEMBLY

6. Use the Phillips screwdriver to install the handle of the tilt lever (*4) with 2 screws (*3).

SMIL14II00178AB

13

SMIL14II00179AB

14

7. Use the Phillips screwdriver or box wrench 10 mm to install the 2 bolts (*2) for the console top cover and cover the control lever boot (*1).

3-24 EN

3 - ASSEMBLY

Tank indicator sensor installation (filter clog warning)

SMIL14CEX5814GB

1

1. Install the tee (56) and pressure sensor (57) on the hydraulic tank (*1). Install the sensor wire harness (58) on the pressure sensor (57). Fasten the sensor wire harness (58) with 2 clamps with band (59) and 2 special bolts (60).

• Tightening torque: 23.5 - 35.3 N·m (17.33 - 26.04 lb ft)

SMIL14CEX5815AB

2

3-25 EN

3 - ASSEMBLY

2. Install the sensor wire harness (58) to the frame wire harness (*2).

SMIL14CEX5816AB

3

3-26 EN

3 - ASSEMBLY

Installation of nameplate inside cab

SMIL14II01084GB

1

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

2. Attach the foot control operation label ( ISO) (75).

3-27 EN

3 - ASSEMBLY

3-28 EN

Index ###_Index_###

B Boom line installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1

C Control lever installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 H Harness installation - Proportional control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 I Installation of nameplate inside cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 K Kit content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

P Pilot line installation - proportional control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 T Tank indicator sensor installation (filter clog warning) . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 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