CNH CX145C SR Crawler Excavator Double-Acting Circuit Proportional Control Kit Instructions Manual

INSTALLATION INSTRUCTIONS

KG0MP902-00

DOUBLE-ACTING CIRCUIT PROPORTIONAL CONTROL KIT

APPROXIMATE INSTALLATION TIME: 25.0 hours

Tor - 47724366 Issue date July 2014 EN

KG0MP902-00 - DOUBLE-ACTING CIRCUIT PROPORTIONAL CONTROL KIT CASE CONSTRUCTION CX145C SR

Tor - 47724366 Issue date July 2014 EN

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

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

3 ASSEMBLY DOUBLE-ACTING CIRCUIT PROPORTIONAL CONTROL KIT Installation of base boom seating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Installation of transverse boom seating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Boom line installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Upper main line installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Pilot line installation - proportional control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Harness installation - proportion control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Control lever installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Control lever installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Port relief valve installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 Installation of nameplate inside cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

EN

EN

1 - KIT CONTENT

1 - KIT CONTENT Kit content Control lever (right) (Refer to 3-19) Item 1

Description Knob (right) proportional control

Quantity 1

Part Reference KHJ28550

Quantity 1

Part Reference KHJ29080

Quantity 1 6 2 1 2 1 2 2 8 1 1 1 4 8 2

Part Reference KMJ17620 KHJ1360 KAR0017 MFV0126 KHJ1941 KMJ15310 KHJ14700 KRJ12170 105R012Y030R KMJ17100 KMJ17810 KMJ17800 KRJ2681 108R010Y030R KHJ0913

Control lever (left) (Refer to 3-23) Item 1

Description 4-switch knob (left)

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

Description Assembly hose O-ring Wire band (L = 380) Bushing ( G1) Hose adapter Hydraulic hose Elbow Manifold Sems bolt ( M12 X 30) Bracket Bracket Hydraulic hose Split flange Hexagon socket head bolt ( M10 X 30) O-ring

Double-acting pilot circuit proportional control (Refer to 3-11) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Description Sems bolt ( M8 X 16) Bracket Assembly hose Wire band (L = 250) Hose adapter ( G1/4) Hose adapter with filter ( G1/4) Assembly hose Hose adapter with filter Pressure switch Sems bolt ( M10 X 20) Reducing valve Stud with filter ( G1/4) Elbow ( G1/4) Tee ( G1/4)

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

Part Reference 105R008Y016R KHJ28770 KMJ17270 KHH0142 KAJ3807 KHJ0917 KMJ17260 KHJ0994 KHR21500 105R010Y020R MFJ71500 KHJ25100 KHJ0348 KHJ0869

Quantity 1 2

Part Reference KHR35680 KHR1317

Electrical part (Refer to 3-16) Item 1 2

Description Option (proportional control) offset wire harness Clip 1-1

EN

1 - KIT CONTENT

Item 3 4 5 6

Description Sems bolt ( M8 X 16) Wire band (L = 250) Mount clamp Phillips pan head screw ( M6 X 8)

Quantity 2 4 3 3

Part Reference 105008Y016R KHH0142 KHR0319 145N006S008R

Quantity 2

Part Reference KMJ2914

Quantity 1

Part Reference KHP21120

Quantity 4 2 2 2 2 2 2 8 4 2

Part Reference 105R012Y060R 102R012Y080R KMV2491 KHJ2023 KMV2961 KRJ0727 KHV10450 105R012Y030R KHV10460 KHN0296

Quantity 1 1 2 1 1 2 2 8 2

Part Reference KMV16360 KMV16350 KMV2306 KMV19710 KMV19700 BRJ1286 KMV2744 KHJ1360 KHJ2041

Quantity 2

Part Reference KRV0482

Quantity 3

Part Reference KHV10540

Port relief valve (Refer to 3-27) Item 1

Description Port relief valve

Plate (Refer to 3-28) Item 1

Description Operation label (proportional control)

Clamp (Refer to 3-4) Item 1 2 3 4 5 13 14 15 16 18

Description Sems bolt ( M12 X 60) High-strength bolt ( M12 X 80) Clamp Hose clamp Bracket Pipe clamp Pipe clamp Sems bolt ( M12 X 30) Pipe clamp High-strength washer ( M12)

Line (Refer to 3-4) Item 6 7 8 9 10 11 12 17 19

Description Line assembly (right) Line assembly (left) Hydraulic hose Line assembly (right) Line assembly (left) Plug ( G3/4) Hydraulic hose O-ring Hose adapter

Base boom seating (Refer to 3-1) Item 1

Description Seating

Transverse boom seating (Refer to 3-3) Item 1

Description Seating

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) • Hexagon wrench ( 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 oil tank.

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

2-2 EN

3 - ASSEMBLY

3 - ASSEMBLY DOUBLE-ACTING CIRCUIT PROPORTIONAL CONTROL KIT

Installation of base boom seating

SMIL14II00479GB

1

3-1 EN

3 - ASSEMBLY

1. Install the 2 seatings (1) on the boom.

• Seal the locations indicated with a.

• Do not weld over the widths indicated with b.

SMIL14II00480BB

2

3-2 EN

3 - ASSEMBLY

Installation of transverse boom seating

SMIL14II00481FB

1

1. Install the 3 seatings (1) on the boom.

• Seal the locations indicated with a.

• Do not weld over the widths indicated with b (both sides).

SMIL14II00482AB

2

3-3 EN

3 - ASSEMBLY

Boom line installation

SMIL14II00483GA

1

1. Set the line assembly (right) (6) and line assembly (left) (7).

SMIL14II00484AB

2

3-4 EN

3 - ASSEMBLY

2. Sandwich the line assembly (left) (7) with 2 pipe clamps (16), and then fasten with 2 sems bolts (15).

• Fasten the pipe clamp (16) at a position 105 mm (4.13 in) from the end of the line assembly (left) (7).

• Remove the line assembly (right) (6) with the same procedure.

SMIL14II00485AB

3

SMIL14II00486AB

4

SMIL14II00487BB

5

3. Sandwich the line assembly (right) (6) and line assembly (left) (7) with 2 pipe clamps (14), and then fasten with 2 sems bolts (15).

4. Set the line assembly (right) (9) and line assembly (left) (10).

Fasten the line assembly (right) (9) and line assembly (left) (10) at 2 locations with 1 pipe clamp (13) each and 1 sems bolt (1) each, and then install the 2 plugs (11).

• Fasten the pipe clamps (13) at positions 100 mm (3.94 in) from the end of the line assembly (right) (9) and the line assembly (left) (10).

3-5 EN

3 - ASSEMBLY

5. Set 1 O-ring (17) each on the line assembly (right) (6) and line assembly (right) (9), and then connect with the hydraulic hose (8).

Set 1 O-ring (17) each on the line assembly (left) (7) and line assembly (left) (10), and then connect with the hydraulic hose (8).

SMIL14II00488BB

6

SMIL14II00015BB

7

6. Set 1 O-ring (17) each on the line assembly (right) (9) and hose adapter (19), and then connect with the hydraulic hose (12).

• Fasten the hydraulic hose (12) on the bracket (*1) with the hose adapter (19).

Set 1 O-ring (17) each on the line assembly (left) (10) and hose adapter (19), and then connect with the hydraulic hose (12).

• Fasten the hydraulic hose (12) on the bracket (*1) with the hose adapter (19).

3-6 EN

3 - ASSEMBLY

7. Connect the line assembly (left) (7) with the hydraulic hose (*2).

Install the bracket (5) on the boom with the sems bolt (15).

Fasten the hydraulic hose (*2) to the bracket (5) with the hose clamp (4) and clamp (3), sems bolt (1), highstrength bolt (2), and high-strength washer (18).

SMIL14II00490BB

8

8. Install on the right side with the same procedure.

3-7 EN

3 - ASSEMBLY

Upper main line installation

SMIL14II00539FB

1

1. Install the manifold (8) on the bracket (10) with 2 sems bolts (9).

Install the bracket (10) on the housing frame (*1) with 2 sems bolts (9).

Install the manifold (8) on the bracket (11) with 2 sems bolts (9).

Install the bracket (11) on the housing frame (*1) with 2 sems bolts (9).

SMIL14II00540BB

2

3-8 EN

3 - ASSEMBLY

2. Install the elbow (7) on the cab side manifold (8), then set the O-ring (2) and connect the hydraulic hose (6).

• Tightening torque: 162 - 198 N·m (119 - 146 lb ft).

SMIL14II00740AB

3

SMIL14II00542BB

4

SMIL14II00741AB

5

3. Set the O-ring (15) on the hydraulic hose (6), then connect the hydraulic hose (6) to the control valve (*2) A2 port with 2 split flanges (13) and 4 hexagon socket head bolts (14).

4. Install the elbow (7) on the boom side manifold (8), then set the O-ring (2) and connect the hydraulic hose (12).

3-9 EN

3 - ASSEMBLY

5. Set the O-ring (15) on the hydraulic hose (12), then connect the hydraulic hose (12) to the control valve (*2) B2 port with 2 split flanges (13) and 4 hexagon socket head bolts (14).

SMIL14II00544BB

6

SMIL14II00545BB

7

6. Install the hose adapter (5) on the cab side manifold (8), then set the O-ring (2) and connect the assembly hose (1/Y1).

• Tightening torque: 162 - 198 N·m (119 - 146 lb ft) Set the O-ring (2) on the line (*4) and connect the assembly hose (1/Y1).

• Tightening torque: 162 - 198 N·m (119 - 146 lb ft) Install the bushing (4) and hose adapter (5) on the boom side manifold (8), then set the O-ring (2) and connect the assembly hose (1/Y2).

• Tightening torque: 162 - 198 N·m (119 - 146 lb ft) Set the O-ring (2) on the line (*5) and connect the assembly hose (1/Y2).

• Tightening torque: 162 - 198 N·m (119 - 146 lb ft) Adjust the hose lengths so that the lengths from the assembly hose (1/Y1) and (1/Y2) ends to the clamp (*6) are the dimensions shown below.

Hose ID Y1 Y2

Dimension (L) 1400 mm (55.1 in) 1420 mm (55.9 in)

Tie the assembly hoses (1/Y1) and (1/Y2) with 2 wire bands (3).

3-10 EN

3 - ASSEMBLY

Pilot line installation - proportional control

SMIL14II00601FB

1

3-11 EN

3 - ASSEMBLY

SMIL14II00602FB

a. b.

Hose assembly Code

*1. *2. *3.

2

Control valve Manifold Floor

1. Install the reducing valve (11) on the bracket (2) with 2 sems bolts (1).

SMIL14II00603AB

3

SMIL14II00604AB

4

2. Install the bracket (2) on the floor (*3) with 2 sems bolts (10).

3-12 EN

3 - ASSEMBLY

3. Install the hose adapter (5) on the reducing valve (11) A2 port.

SMIL14II00605AB

5

SMIL14II00606BB

6

SMIL14II00607AB

7

4. Install the hose adapter with filter (6) on the control valve (*1) Pa2 port.

Connect the reducing valve (11) A2 port and control valve (*1) Pa2 port with the assembly hose (7/Y1).

5. Install the hose adapter (5) on the reducing valve (11) A1 port.

3-13 EN

3 - ASSEMBLY

6. Install the hose adapter with filter (8) on the control valve (*1) Pb2 port.

Connect the reducing valve (11) A1 port and control valve (*1) Pb2 port with the assembly hose (7/Y2).

SMIL14II00608BB

8

SMIL14II00609AB

9

7. Install the stud with filter (12) and elbow (13) on the reducing valve (11) P port.

8. Install the tee (14) on the manifold (*2) P5 port.

Connect the reducing valve (11) P port and manifold (*2) P5 port with the assembly hose (3/P6).

Install the tee (14) on the manifold (*2) T5 port.

SMIL14II00610AB

10

3-14 EN

3 - ASSEMBLY

9. Install the elbow (13) on the reducing valve (11) T port.

Connect the reducing valve (11) T port and manifold (*2) T5 port with the assembly hose (3/T6).

SMIL14II00611AB

11

SMIL14II00612AB

12

10. Fasten the assembly hoses with the wire band (4).

Install the 2 pressure switches (9) on the reducing valve (11).

3-15 EN

3 - ASSEMBLY

Harness installation - proportion control

SMIL14II00533FB

1

SMIL14II00534FB

2

3-16 EN

3 - ASSEMBLY

* The quantity of parts varies depending on the specifications.

1. For double-acting circuit, connect the wire harness (1) and the reducing valve (*1) as shown in the diagram.

• The ID tape (*2) is a red tape and (*3) is a blue tape.

Fasten the 2 couplers on the wire harness with 1 clip (2) each and 1 sems bolt (3) each.

SMIL14II00535AB

3

SMIL14II00536AB

4

SMIL14II00537BB

5

2. For breaker circuit, connect the wire harness (1) and the reducing valve (*1) as shown in the diagram.

• The ID tape (*2) is a red tape and (*3) is a blue tape.

Fasten the 2 couplers on the wire harness with 1 clip (2) each and 1 sems bolt (3) each.

3. When the kit comes with a screw cap, install the screw cap (7) on the floor.

3-17 EN

3 - ASSEMBLY

4. Route the wire harness (1) as shown in the diagram.

Fasten the wire harness (1) at 3 locations with 1 wire band (4) each, 1 mount clamp (5) each, and 1 Phillips pan head screw (6) each.

SMIL14II00538BB

6

SMIL14II00476AB

7

5. Extend the wire harness (1) to the floor side from under the cab.

Connect the wire harness (1) connector (16-pin) to the cab main harness (*4).

3-18 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).

3-19 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)

3-20 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.

3-21 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).

3-22 EN

3 - ASSEMBLY

Control lever installation Removal of control lever (left) 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.

SMIL14II00077AB

1

SMIL14II00078AB

2

SMIL14II00079AB

3

SMIL14II00080AB

4

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

3. Use a hexagon wrench [ 5 mm] to remove the 2 bolts (*5), and remove the grip (*6) of the gate lock lever.

4. Use the Phillips screwdriver to remove the 2 screws (*7) of the console top cover.

3-23 EN

3 - ASSEMBLY

5. Remove the connector (*8) and remove the console top cover (*9).

SMIL14II00081AB

5

SMIL14II00082AB

6

SMIL14II00083AB

7

SMIL14II00084AB

8

6. Use a Phillips screwdriver or box wrench [ 10 mm] to remove the 5 bolts (*10) and remove the cover (*11).

7. Roll up the boot (*12) of the control lever, remove the connector (*13) of the lever switch, and cut the wire band (*14).

8. While fastening the nut (*15) with a wrench [ 22 mm], use a wrench [ 19 mm] to remove the lock nut (*16) and remove the control lever (*17).

3-24 EN

3 - ASSEMBLY

Installation of control lever (left) 1. After installing the knob (left) (1), while fastening the nut (*15) with a wrench [ 22 mm], use a wrench [ 19 mm] to install the lock nut (*16).

Lock nut tightening torque: (28.249 - 32.526 lb ft)

38.3 - 44.1 N·m

SMIL14II00085AB

9

2. Install the lever switch connector (*13), bundle with the wire band (*14), and then cover the control lever boot (*12).

SMIL14II00083AB

10

SMIL14II00082AB

11

SMIL14II00086AB

12

3. Use a Phillips screwdriver or box wrench [ 10 mm] to install the cover (*11) with 5 bolts (*10).

4. Install the connector (*8) and install the console top cover (*9).

3-25 EN

3 - ASSEMBLY

5. Use the Phillips screwdriver to install the 2 screws (*7) of the console top cover.

SMIL14II00087AB

13

SMIL14II00088AB

14

SMIL14II00089AB

15

SMIL14II00090AB

16

6. Use a hexagon wrench [ 5 mm] to install the grip (*4) of the gate lock lever with 2 bolts (*5).

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

8. 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).

3-26 EN

3 - ASSEMBLY

Port relief valve installation 1. Remove the plug, and then install the 2 port relief valves (1) on the control valve (*1).

• Tightening torque: 78.4 - 88.3 N·m (57.8 - 65.1 lb ft) After installing the port relief valves (1), adjust the relief pressure to match the attachment used. (See the Service Manual.)

SMIL14II00559BB

1

3-27 EN

3 - ASSEMBLY

Installation of nameplate inside cab

SMIL14II00478GB

1

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

2. Attach the operation label (proportional control) (1).

3-28 EN

Index ###_Index_###

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

C Control lever installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4

3-19, 3-23

H Harness installation - proportion control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 I Installation of base boom seating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Installation of nameplate inside cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 Installation of transverse boom seating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 K Kit content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

P Pilot line installation - proportional control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Port relief valve installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 U Upper main line installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8

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