CNH Breaker circuit proportional control Kit CX250D Crawler Excavator Instructions Manual

INSTALLATION INSTRUCTIONS

KG1BP441-00

BREAKER CIRCUIT PROPORTIONAL CONTROL KIT

APPROXIMATE INSTALLATION TIME: 28.0 hours

San - 47789087 Issue date February 2015 EN

KG1BP441-00 - BREAKER CIRCUIT PROPORTIONAL CONTROL KIT CASE CONSTRUCTION CX250D

San - 47789087 Issue date February 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Tank indicator sensor installation (filter clog warning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Installation of nameplate inside cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

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 3-20) Item 1

Description Knob (right) proportional control

Quantity 1

Part Reference KHJ28550

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

Part Reference KBJ22370 KHJ0914 KRJ2682 108R010Y030R KHJ1349 KHJ1361 KRJ11470 105R012Y030R KHJ15050 KSJ13741 KRJ16400 KRJ16050 KRJ11540 KHJ0351 KBJ22210 KHJ0345 KHJ0352 KHH0142

Quantity 1 2 1 2 1 1 1 1 1 1 1 1 1 7 1 2 3 3 4

Part reference MFJ71500 105R008Y016R KHJ28770 105R010Y020R KNJ0758 KAJ3807 KHJ0363 CNA0584 KBJ22350 KHR26940 KBJ22360 KHJ28880 KHJ28690 KHH0143 KNJ0758 KHJ28580 KHR0319 145N006S008R KHH0142

Breaker main circuit (Refer to 3-5) Item 24 25 26 27 28 29 30 31 32 34 35 38 40 41 42 43 44 45

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

Breaker pilot circuit, proportional control (Refer to 3-12) Item 30 31 32 33 34 35 36 37 38 39 40 41 42 43 45 46 47 48 49

Description Reducing valve Sems bolt M8x16 Bracket Sems bolt M10x20 Hose adapter G1/4 Tee G1/4 Plug G1/4 Nipple with filter G1/4 Assembly hose Pressure sensor Assembly hose Elbow Elbow Wire band (L = 300) Hose adapter G1/4 Elbow G1/4 Mount clamp Phillips pan head screw M6x8 Wire band (L = 250)

1-1 EN

1 - KIT CONTENT

Electrical part (Refer to 3-17) Item 66 67 68 69

Description

Quantity 1 8 3 3

Part reference KHR39501 KHH0142 KHR1957 KHR1253

Description Tee G1/4 x G3/8 Pressure sensor G1/4 Sensor wire harness Mount clamp Wire band (L = 250) Clip Special bolt M8x16

Quantity 1 1 1 2 2 1 1

Part reference KHJ12530 KHR32870 KHR33420 KHR10220 KHH0142 KHR1317 KHJ1213

Quantity 1

Part reference KHP27030

Description

Quantity 8 4 4 2

Part Reference KHV10610 KHV10630 105R012Y030R KHV10640

Description (left-hand) (left-hand)

Quantity 1 1 2 2 1 1

Part Reference KBV31230 KBV23610 KHJ1361 BRJ1286 KBV31240 KBV23630

Quantity 2 2

Part Reference KHJ1899 KHJ1361

Wire harness Wire band (L = 250) Clip Bolt M6x16

Indicator (Refer to 3-24) Item 64 65 66 67 68 69 70

Plate (Refer to 3-25) Item 75

Description Operation label (proportional control)

Clamp (Refer to 3-1) Item 86 87 88 89

Pipe clamp Pipe clamp Sems bolt M12x30 Pipe clamp

Line (Refer to 3-1) Item 91 92 93 94 95 96

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

(right-hand) (right-hand)

Plug (Refer to 3-1) Item 100 101

Description Plug O-ring

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

SMIL15CEX2466GB

1

3-1 EN

3 - ASSEMBLY

Line assemblies (92) and (96) 1. Set the line assembly (left) (92) on the boom.

SMIL15CEX2467AB

2

SMIL15CEX2468AB

3

SMIL15CEX2469AB

4

2. Sandwich the line assembly (left) (92) at two locations with two pipe clamps (86) each, and then fasten with two sems bolts (*1) each.

• Fasten 1 pipe clamp (86) at a position 265 mm (10 in) from the rear end of the line assembly (left) (92).

3. Install the plug (94) on the line assembly (left) (92).

3-2 EN

3 - ASSEMBLY

4. Sandwich the line assembly (left) (92) with two pipe clamps (87), and then fasten with two sems bolts (*2).

• Fasten the pipe clamp (87) at a position 205 mm (8 in) from the front end of the line assembly (left) (92).

5. Install the line assembly (right) (96) in the same way as the line assembly (left) (92).

SMIL15CEX2470BB

5

SMIL15CEX2471BB

6

Line assemblies (91) and (95) 1. Set the line assembly (left) (91).

3-3 EN

3 - ASSEMBLY

2. Fasten the line assembly (left) (91) with the one pipe clamp (89) and the two sems bolts (88).

• Fasten the pipe clamp (89) at a position 150 mm (6 in) from the front end of the line assembly (left) (91).

SMIL15CEX2472AB

7

SMIL15CEX2473AB

8

SMIL15CEX2474AB

9

3. Set the O-ring (93) on the rear end of the line assembly (left) (91), and then connect the line assembly (left) (92).

4. Set the O-ring (101) on the front end of the line assembly (left) (91), and then install the plug (100).

5. Install the line assembly (right) (95) in the same way as the line assembly (left) (91).

3-4 EN

3 - ASSEMBLY

Upper main line installation

SMIL15CEX2475GB

1

3-5 EN

3 - ASSEMBLY

Upper main line installation (left side) 1. Install the bracket (30) on the frame with four sems bolts (31).

Install the relief valve (32) on the bracket (30) with the two sems bolts (31).

• Adjust the set pressure for the relief valve (32) to match the type of attachment used.

SMIL15CEX2476BB

2

SMIL15CEX2477BB

3

2. Install the hose adapter (28) on the relief valve (32) A port.

Set the O-ring (29) on the hose adapter (28) and connect the hydraulic hose (34).

3-6 EN

3 - ASSEMBLY

3. Set the O-ring (29) on the hydraulic hose (34) and connect to the line assembly (left) (*3).

SMIL15CEX2478BB

4

SMIL15CEX2479BB

5

4. Install the hose adapter (28) on the relief valve (32) B port.

Set the O-ring (29) on the hose adapter (28) and install the hydraulic hose (24).

3-7 EN

3 - ASSEMBLY

5. Set the O-ring (25) on the control valve (*1) A2 port, and install the hydraulic hose (24) with two split flanges (26) and four hexagon socket head bolts (27).

SMIL15CEX2480BB

6

SMIL15CEX2481BB

7

Upper main line installation (right side) 1. Install the bracket (38) on the frame with four sems bolts (31).

3-8 EN

3 - ASSEMBLY

2. Install the manifold (35) on the bracket (38) with two sems bolts (31). Install the hose adapter (28) on the manifold (35) line assembly (right side) (*4).

Set the O-ring (29) on the hose adapter (28) and connect the hydraulic hose (34) .

SMIL15CEX2482BB

8

SMIL15CEX2483BB

9

3. Set the O-ring (29) on the hydraulic hose (34) and connect to the line assembly (*4).

3-9 EN

3 - ASSEMBLY

4. Install the elbow (44) on the manifold (35) hydraulic tank (*2) side.

Connect the hydraulic hose (42) to the elbow (44).

SMIL15CEX2484BB

10

SMIL15CEX2485BB

11

5. Install the elbow (43) on the hydraulic tank (*2).

Connect the hydraulic hose (42) to the elbow (43).

3-10 EN

3 - ASSEMBLY

6. Install the elbow (41) on the relief valve (32) T port.

Install the elbow (41) on the manifold (35) relief valve side.

Connect the relief valve (32) T port and manifold (35) relief valve side with the hydraulic hose (40).

SMIL15CEX2486AB

12

SMIL15CEX2487AB

13

SMIL15CEX2488AB

14

3-11 EN

3 - ASSEMBLY

Pilot line installation - proportional control

SMIL15CEX2508FB

SMIL14II01063FB

1

2

3-12 EN

3 - ASSEMBLY

SMIL15CEX2509FB

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 (30) on the bracket (32) with two sems bolts (31).

2. Install the bracket (32) on the floor (*1) with two sems bolts (33).

SMIL15CEX2510AB

4

SMIL15CEX2511AB

5

SMIL15CEX2512AB

6

SMIL15CEX2513AB

7

3. Install the hose adapter (34) on the reducing valve (30) T port.

4. Install the elbow (46) on the manifold (*2) T5 port. Connect the reducing valve (30) T port and manifold (*2) T5 port with the assembly hose (38) (T5).

5. Install the nipple with filter (37) on the reducing valve (30) P port.

3-14 EN

3 - ASSEMBLY

6. Install the elbow (46) on the manifold (*2) P5 port. Connect the reducing valve (30) P port and manifold (*2) P5 port with the assembly hose (38) (P5).

SMIL15CEX2515AB

8

SMIL15CEX2516AB

9

7. Install the plug (36) on the reducing valve (30) A1 port.

Install the tee (35) on the reducing valve (30) A2 port.

8. Install the elbow (41) on the control valve (*3) pa2 port.

Connect the reducing valve (30) A2 port and control valve (*3) pa2 port with the assembly hose (38) (Y1).

A. Left

SMIL15CEX2517BB

10

3-15 EN

3 - ASSEMBLY

9. Install the elbow (42) on the control valve (*3) pb2 port.

Install the hose adapter (45) on the hydraulic tank (*4).

Connect the control valve (*3) pb2 port and the hydraulic tank (*4) with the assembly hose (40) (Y2).

• Fasten the assembly hose (40) (Y2) together with the pilot control line.

SMIL15CEX2518BB

11

SMIL15CEX2519AB

12

10. Fasten the assembly hose that comes out from the reducing valve (30) with three mount clamps (47), three Phillips pan head screws (48), and four wire bands (49).

Install the pressure sensor (39) on the reducing valve (30).

3-16 EN

3 - ASSEMBLY

Harness installation - Proportional control

SMIL15CEX2520FB

1

SMIL15CEX2521FB

2

3-17 EN

3 - ASSEMBLY

1. Connect the wire harness (66) and the reducing valve (*1).

SMIL15CEX2522AB

3

SMIL15CEX2523BB

4

SMIL15CEX2524AB

5

2. Route the wire harness (66) as shown in the diagram.

Fasten the wire harness (66) at six locations with six wire bands (67).

3. Fasten the three couplers on the wire harness (66) with one clip (68) each and one bolt (69) each.

3-18 EN

3 - ASSEMBLY

4. Connect the wire harness (66) connector (8-pin) to the frame main harness (*3) and fasten with the wire band (67)

SMIL15CEX2525AB

6

SMIL15CEX2526AB

7

5. Extend the wire harness (66) to the floor side from under the cab.

Connect the wire harness (66) connector (16-pin) to the cab main harness and fasten with the wire band (67).

3-19 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).

3-20 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)

3-21 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.

3-22 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).

3-23 EN

3 - ASSEMBLY

Tank indicator sensor installation (filter clog warning)

SMIL15CEX3045FB

1

1. Remove the elbow and pilot P and T lines from the hydraulic tank (*1) manifold, and then install the tee (64).

2. Install the pressure sensor (65) on the tee (64).

Connect the sensor wire harness (66) to the pressure sensor (65).

SMIL15CEX2527AB

2

SMIL15CEX2528AB

3

3. Connect the sensor wire harness (66) to the frame main wire harness (*4).

Fasten the sensor wire harness (66) with the special bolt (70) and the clip (69).

3-24 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).

3-25 EN

3 - ASSEMBLY

3-26 EN

Index ###_Index_###

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

3-1

C Control lever installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 H Harness installation - Proportional control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 I Installation of nameplate inside cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 K Kit content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

P Pilot line installation - proportional control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 T Tank indicator sensor installation (filter clog warning) . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 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