CNH Breaker Circuit Proportional Control CX350D Crawler Excavator Installation Instructions Manual

INSTALLATION INSTRUCTIONS

KG1SP077-00

BREAKER CIRCUIT PROPORTIONAL CONTROL KIT

APPROXIMATE INSTALLATION TIME: 28.0 hours

Tor - 47757378 Issue date September 2014 EN

KG1SP077-00 - BREAKER CIRCUIT PROPORTIONAL CONTROL KIT CASE CONSTRUCTION CX350D

Tor - 47757378 Issue date September 2014 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Pilot line installation - proportional control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Harness installation - Proportional control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Control lever installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Tank indicator sensor installation (filter clog warning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 Installation of nameplate inside cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

EN

EN

1 - KIT CONTENT

1 - KIT CONTENT Kit content NA

CX350D

NOTE: Please refer to the Parts Manual for parts orders.

Control lever (right) (Refer to 3-25) Item 1

Description Knob (right) proportional control

Quantity 1

Part Reference KHJ28550

Quantity 1 1 2 4 1 1 1 1 1 2 4 1 1 2 2 4 8 1 1 1 1 1 2 4 1 1 1 1 1 1 2 1 1 1 1

Part Reference KSJ19080 KHJ0914 KRJ2682 108R010Y030R KHJ1361 KHJ1349 KHJ25900 KHJ15050 KSJ17120 105R012Y030R KHN1079 KHJ11370 KHJ1361 KSJ19110 M20J0771 KTJ0029 108R014Y055R KHJ1361 KHJ1349 KHJ25900 KRJ16400 KSJ16040 105R012Y030R KHN1079 KNJ0605 KSJ17140 KNJ0605 KTJ1261 KSJ19130 KBJ15230 105R012Y030R KHJ2680 KBJ11860 105R012Y030R KHJ0345

Quantity 1 2

Part reference MFJ71500 105R008Y016R

Breaker main circuit (Refer to 3-9) Item 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

Description Hydraulic hose O-ring Split flange ( G1) Hexagon socket head bolt ( M10 x 30) O-ring Hose adapter Socket Relief valve Bracket Sems bolt ( M12 x 30) Special bolt ( M12 x 25) Elbow O-ring Hydraulic hose O-ring Split flange ( G1 x 1/4) Hexagon socket head bolt ( M14 x 55) O-ring Hose adapter Socket Manifold Bracket Sems bolt ( M12 x 30) Special bolt ( M12 x 25) Hose adapter ( G3/4) Hydraulic hose Hose adapter ( G3/4) Stud Hydraulic hose Bracket Sems bolt ( M12 x 30) Hose clamp Bracket Sems bolt ( M12 x 30) Elbow ( G1)

Breaker pilot circuit, proportional control (Refer to 3-16) Item 42 43

Description Reducing valve Sems bolt ( M8 x 16) 1-1

EN

1 - KIT CONTENT

Item 44 45 46 47 48 49 50 51 53 54 55 56 58 60 61 62 63

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

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

Part reference KHJ28770 105R010Y020R KNJ0758 CNA0584 KAJ3807 KHJ0363 KSJ21130 KHH0142 KHJ28690 KSJ20360 KNJ0758 KHH0142 KHR26940 KHJ28580 KHR0319 145N006S008R KHH0142

Quantity 1 2 3 3

Part reference KHR39500 KHH0142 KHR1957 KHR1253

Quantity 1 1 2 2 1

Part reference KHR32870 KHR42050 KHR2584 KHJ1215 KHH0142

Quantity 1

Part reference KHP27030

Quantity 8 4 4 2

Part Reference KHV11200 KHV11060 105R012Y030R KHV11070

Quantity 1 1 1 2 4

Part Reference KSV24530 KSV24541 M20J0771 KTJ0029 108R014Y050R

Electrical part (Refer to 3-21) Item 81 82 83 84

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

Indicator (Refer to 3-29) Item 66 67 68 69 70

Description Pressure sensor ( G1/4) Sensor wire harness Clamp with band ( M8) Special bolt ( M8 x 25) Wire band (L = 250)

Plate (Refer to 3-31) Item 75

Description Operation label (proportional control)

Clamp (Refer to 3-1) Item 88 89 90 91

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

Line (Refer to 3-1) Item 93 94 95 96 97

Description Line assembly (left) Line assembly (left) O-ring Split flange ( G1 x 1/4) Hexagon socket head bolt ( M14 x 50) 1-2

EN

1 - KIT CONTENT

Item 98 99 100 101 102 103 104

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

Quantity 1 1 1 1 2 4 2

Part Reference BRJ1286 KSV24560 KSV24571 M20J0771 KTJ0029 108R014Y050R BRJ1286

Quantity 2 2 8

Part Reference KUP0009 M20J0771 108R014Y050R

Plug (Refer to 3-1) Item 107 108 109

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

1-3 EN

1 - KIT CONTENT

1-4 EN

2 - PRE-ASSEMBLY

2 - PRE-ASSEMBLY PREPARING FOR ASSEMBLY

Preparation NA

CX350D

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, 22 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 CX350D

NA

SMIL14II01033FB

1

3-1 EN

3 - ASSEMBLY

Line assemblies (94) and (100) 1. Set the line assembly (left) (94) on the boom.

SMIL14II01034BB

2

SMIL14II01035BB

3

2. Sandwich the line assembly (left) (94) at 2 locations with 2 pipe clamps (88) each, and then fasten with 2 sems bolts (*1) each.

• Fasten 1 pipe clamp (88) at a position 382 mm from the rear end of the line assembly (left) (94).

3-2 EN

3 - ASSEMBLY

3. Install the plug (98) on the line assembly (left) (94).

SMIL14II01036AB

4

SMIL14II01037BB

5

4. Sandwich the line assembly (left) (94) with 2 pipe clamps (89), and then fasten with 2 sems bolts (*2).

• Fasten the pipe clamp (89) at a position 305 mm from the front end of the line assembly (left) (94) .

3-3 EN

3 - ASSEMBLY

5. Set the line assembly (right) (100) on the boom.

SMIL14II01038BB

6

SMIL14II01039BB

7

6. Sandwich the line assembly (right) (100) at 2 locations with 2 pipe clamps (88) each, then fasten with 2 sems bolts (*1) each.

• Fasten 1 pipe clamp (88) at a position 382 mm from the rear end of the line assembly (right) (100).

3-4 EN

3 - ASSEMBLY

7. Install the 2 plugs (104) on the line assembly (right) (100).

SMIL14II01040AB

8

SMIL14II01041BB

9

8. Sandwich the line assembly (right) (100) with 2 pipe clamps (89), and then fasten with 2 sems bolts (*2).

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

3-5 EN

3 - ASSEMBLY

Line assemblies (93) and (99) 1. Set the line assembly (left) (93).

SMIL14II01042BB

10

SMIL14II01043BB

11

2. Fasten the line assembly (left) (93) with the 1 pipe clamp (91) and the 2 sems bolts (90).

• Fasten the pipe clamp (91) at a position 110 mm from the front end of the line assembly (left) (93).

3-6 EN

3 - ASSEMBLY

3. After setting the O-ring (95) on the rear end of the line assembly (left) (93), fasten the line assembly (left) (93) with the 2 split flanges (96) and the 4 hexagon socket head bolts (97).

SMIL14II01044AB

12

SMIL14II01045AB

13

SMIL14II01046BB

14

4. Set the O-ring (108) on the front end of the line assembly (left) (93), then install the flat flange (107) with the 4 hexagon socket head bolts (109).

5. Set the line assembly (right) (99).

3-7 EN

3 - ASSEMBLY

6. Fasten the line assembly (right) (99) with 1 pipe clamp (91) and 2 sems bolts (90).

• Fasten the pipe clamp (91) at a position 110 mm from the front end of the line assembly (right) (99).

SMIL14II01047BB

15

SMIL14II01048AB

16

SMIL14II01049AB

17

7. After setting the O-ring (101) on the rear end of the line assembly (right) (99), fasten the line assembly (right) (99) with the 2 split flanges (102) and the 4 hexagon socket head bolts (103).

8. Set the O-ring (108) on the front end of the line assembly (right) (99), then install the flat flange (107) with the 4 hexagon socket head bolts (109).

3-8 EN

3 - ASSEMBLY

Upper main line installation CX350D

NA

SMIL14II00994FB

1

3-9 EN

3 - ASSEMBLY

Upper main line installation (left side) 1. Install the bracket (12) on the frame with 4 special bolts (14).

Install the relief valve (11) on the bracket (12) with the 2 sems bolts (13).

• Adjust the set pressure for the relief valve (11) to match the type of attachment used.

SMIL14II01050BB

2

SMIL14II01051BB

3

2. Install the socket (10) on the relief valve (11) B port to connect the hose adapter (9).

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

3-10 EN

3 - ASSEMBLY

3. Set the O-ring (18) on the assembly hose (17), then connect to the line assembly (left) (*3) with the 2 split flanges (19) and the 4 hexagon socket head bolts (20).

SMIL14II01052BB

4

SMIL14II01053BB

5

4. Install the elbow (15) on the relief valve (11) A port.

Set the O-ring (16) on the elbow (15) and connect the hydraulic hose (4).

3-11 EN

3 - ASSEMBLY

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

SMIL14II01054BB

6

SMIL14II01055BB

7

Upper main line installation (right side) 1. Install the bracket (26) on the frame with 4 special bolts (28).

3-12 EN

3 - ASSEMBLY

2. Install the manifold (25) on the bracket (26) with 2 sems bolts (27).

Install the socket (24) on the manifold (25) line assembly (right) (*4) side to connect the hose adapter (23).

Set the O-ring (22) on the hose adapter (23) and connect the hydraulic hose (17).

SMIL14II01056BB

8

SMIL14II01057BB

9

3. Set the O-ring (18) on the hydraulic hose (17), then connect to the line assembly (*4) with 2 split flanges (19) and 4 hexagon socket head bolts (20).

3-13 EN

3 - ASSEMBLY

4. Install the stud (32) on the manifold (25) hydraulic tank (*2) side.

Connect the hydraulic hose (33) to the stud (32).

SMIL14II01058BB

10

SMIL14II01059BB

11

5. Install the elbow (39) on the hydraulic oil tank (*2) hose (*5).

Connect the hydraulic hose (33) to the elbow (39).

3-14 EN

3 - ASSEMBLY

6. Install the bracket (34) on the housing frame with 2 sems bolts (35).

Set the hose clamp (36) on the hydraulic hose (33), and then install the bracket (37) on the bracket (34) with the sems bolt (38).

SMIL14II01060BB

12

SMIL14II01061BB

13

7. Install the hose adapter (31) on the relief valve (11) T port.

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).

3-15 EN

3 - ASSEMBLY

Pilot line installation - proportional control CX350D

NA

SMIL14II01062FB

1

SMIL14II01063FB

2

3-16 EN

3 - ASSEMBLY

SMIL14II01064FB

a. b. *1.

Hose assembly Code Floor

*2. *3. *4.

3

Manifold Control valve Hydraulic tank

1. Install the reducing valve (42) on the bracket (44) with 2 sems bolts (43).

2. Install the bracket (44) on the floor (*1) with 2 sems bolts (45).

SMIL14II01065AB

4

SMIL14II01066AB

5

3. Install the hose adapter (46) on the reducing valve (42) T port.

3-17 EN

3 - ASSEMBLY

4. Install the elbow (60) on the manifold (*2) T5 port.

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

SMIL14II01067AB

6

SMIL14II01068AB

7

SMIL14II01069AB

8

SMIL14II01070AB

9

5. Install the nipple with filter (47) on the reducing valve (42) P port.

6. Install the elbow (60) on the manifold (*2) P5 port.

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

7. Install the plug (49) on the reducing valve (42) A1 port.

Install the hose adapter (48) on the reducing valve (42) A2 port.

3-18 EN

3 - ASSEMBLY

8. Install the elbow (53) on the control valve (*3) pa2 port.

Connect the reducing valve (42) A2 port and control valve (*3) pa2 port with the assembly hose (50/Y1).

SMIL14II01071BB

10

SMIL14II01072BB

11

9. Install the elbow (53) on the control valve (*3) pb2 port.

Install the hose adapter (55) on the hydraulic tank (*4) D11 port.

Connect the control valve (*3) pb2 port and hydraulic tank (*4) D11 port with the assembly hose (54/Y2).

• Tighten the assembly hose (54/Y2) together with the pilot control line.

3-19 EN

3 - ASSEMBLY

10. Fasten the assembly hoses (50/Y1), (50/P5) and (50/ T5) that come out from the reducing valve (42) at 4 locations with 1 mount clamp (61) each, 1 Phillips pan head screw (62) each, and 1 wire band (63) each.

Fasten the assembly hoses (50/P5) and (50/T5) that come out from the reducing valve (42) with the wire band (51).

• Fasten the assembly hoses (50/P5) and (50/T5) together with the pilot control line.

Install the pressure sensor (58) on the reducing valve (42).

SMIL14II01073BB

12

3-20 EN

3 - ASSEMBLY

Harness installation - Proportional control CX350D

NA

SMIL14II01074FB

1

SMIL14II01075FB

2

3-21 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).

3-22 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)

3-23 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

3-24 EN

3 - ASSEMBLY

Control lever installation NA

CX350D

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

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.

3-25 EN

3 - ASSEMBLY

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

SMIL14II00170AB

4

SMIL14II00175AB

5

SMIL14II00171AB

6

SMIL14II00172AB

7

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

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).

3-26 EN

3 - ASSEMBLY

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)

SMIL14II00173AB

8

SMIL14II00174AB

9

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

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

SMIL14II00175AB

10

SMIL14II00176AB

11

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

3-27 EN

3 - ASSEMBLY

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

SMIL14II00177AB

12

SMIL14II00178AB

13

SMIL14II00179AB

14

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

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).

3-28 EN

3 - ASSEMBLY

Tank indicator sensor installation (filter clog warning) CX350D

NA

SMIL14II01081GB

1

3-29 EN

3 - ASSEMBLY

1. Install the pressure sensor (66) on the hydraulic tank (*1).

Install the sensor wire harness (67) on the pressure sensor (66), then fasten with the wire band (70).

Fasten the sensor wire harness (67) with the clamp with band (68) and special bolt (69).

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

SMIL14II01082BB

2

SMIL14II01083BB

3

2. Install the sensor wire harness (67) to the frame wire harness (*2).

3-30 EN

3 - ASSEMBLY

Installation of nameplate inside cab NA

CX350D

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).

3-31 EN

3 - ASSEMBLY

3-32 EN

Index ###_Index_###

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

3-1

C Control lever installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 H Harness installation - Proportional control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 I Installation of nameplate inside cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 K Kit content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

P Pilot line installation - proportional control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 T Tank indicator sensor installation (filter clog warning) . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 U Upper main line installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9

EN

SERVICE - Technical Publications & Tools

© 2014 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