CNH CX145C SR Crawler Excavator Hose Burst Check Valves (HBCV) Kit Installation Instructions Manual

INSTALLATION INSTRUCTIONS

KG0MP816-00

HOSE BURST CHECK VALVES (HBCV) KIT

APPROXIMATE INSTALLATION TIME: 8.0 hours

Tor - 47724388 Issue date July 2014 EN

KG0MP816-00 - HOSE BURST CHECK VALVES (HBCV) KIT CASE CONSTRUCTION CX145C SR

Tor - 47724388 Issue date July 2014 EN

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

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

3 ASSEMBLY HOSE BURST CHECK VALVE (HBCV) KIT ASSEMBLY HBCV Installation on boom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Boom cylinder line installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Installation on arm cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Arm cylinder line installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Pilot line installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Installation of housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

EN

EN

1 - KIT CONTENT

1 - KIT CONTENT Kit content Pilot HBCV (Refer to 3-12) Item 1 2 3 4 5 6 7 8 9 10 11 12

Description Tee ( G1/4) Assembly hose Wire band (L = 250) Tee ( G1/4 x G3/8 x G1/4) Clamp with band ( M8) Special bolt ( M8 X 25) Bracket Sems bolt ( M10 X 20) Assembly hose Wire band (L = 380) Tee ( G1/4-G3/8-G1/4) Bracket

Quantity 2 1 13 1 3 3 1 2 1 1 1 1

Part reference KHJ2773 KMJ16580 KHH0142 KHJ25080 KHR2581 KHJ1215 KMJ15640 105R010Y020R KMJ16610 KAR0017 KHJ11560 KMJ16830

Quantity 2 3 4 1 1 1 1 2 4 5

Part reference KHJ0869 KHJ0894 KNJ0758 KMV18060 KLV11930 KLV13680 KHJ0912 KHV11140 108R008Y025R KAR0017

Quantity 11 1 1 1 1 2 1 1 2

Part reference KAR0016 KHJ1360 KNJ1106 KNJ0759 KHJ0894 KHJ0506 KMV17830 KMV15760 105R010Y025R

Quantity 1 1 1 4 4 1

Part reference KMV18040 KHJ0912 KNV12850 108R010Y060R 108R008Y025R KHJ0913

Boom HBCV line (Refer to 3-4) Item 2 3 4 80 81 82 83 84 85 86

Description Tee ( G1/4 ) Stud ( G1/4 ) Hose adapter ( G1/4) Hydraulic hose Assembly hose Hydraulic hose O-ring Split flange Hexagon socket head bolt ( M8 X 25) Wire band (L = 380)

Arm HBCV line (Refer to 3-10) Item 1 2 7 8 9 87 88 89 90

Description Wire band (L = 150) O-ring Hose adapter ( G1/4-G3/8) Hose adapter ( G3/8 ) Stud ( G1/4) Hose adapter ( G3/8) Assembly hose Bracket Sems bolt ( M10 X 25)

Left boom cylinder (Refer to 3-1) Item 2 5 6 7 8 9

Description Line assembly (left HBCV) O-ring Holding valve Hexagon socket head bolt ( M10 X 60) Hexagon socket head bolt ( M8 X 25) O-ring 1-1

EN

1 - KIT CONTENT

Right boom cylinder (Refer to 3-1) Item 4 5 6

Description Holding valve Hexagon socket head bolt ( M10 X 60) O-ring

Quantity 1 4 1

Part reference KNV12850 108R010Y060R KHJ0913

Quantity 4 1 2 4 1

Part reference 108R010Y070R KNV26480 KHJ0913 108R010Y035R KNV14720

Quantity 1 1

Part Reference KMN14970 KRN10750

Arm cylinder (Refer to 3-8) Item 1 2 3 4 5

Description Hexagon socket head bolt ( M10 X 70) Holding valve O-ring Hexagon socket head bolt ( M10 X 35) Line assembly (HBCV)

House cover (Refer to 3-19) Item 16 39

Description Cover Rubber cushion

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, 22 mm) • Box wrenches ( 13 mm, 17 mm, 19 mm, 22 mm) • Hexagon wrenches ( 6 mm, 8 mm) • 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 HOSE BURST CHECK VALVE (HBCV) KIT ASSEMBLY

HBCV Installation on boom cylinder Installation on left boom cylinder

LPIL12DIA0054FB

1

3-1 EN

3 - ASSEMBLY

1. Remove the bolt ( M12 X 1.75) (*3), then remove the clamp (*2).

Set the O-ring (9) on the holding valve (6), then install on the boom cylinder (left) (*1) with 4 hexagon socket head bolts (7).

• Tightening torque: 41.6 - 60.8 N·m (30.68 - 44.84 lb ft)

LPIL12DIA0096BB

2

LPIL12DIA0324BB

3

2. Set the O-ring (5) on the end of the line assembly (left HBCV) (2), and then install on the holding valve (6) with 4 hexagon socket head bolts (8).

• Tightening torque: 21.4 - 31.2 N·m (15.78 - 23.01 lb ft) Set the line assembly (left HBCV) (2) and line (*4) on the clamp (*2), then fasten with the bolt ( M10 X 1.75) (*3).

• Tightening torque: 46.2 - 67.6 N·m (34.08 - 49.86 lb ft)

3-2 EN

3 - ASSEMBLY

Installation on right boom cylinder

LPIL12DIA0147FB

4

1. Set the O-ring (6) on the holding valve (4), then install on the boom cylinder (right) (*1) with 4 hexagon socket head bolts (5).

• Tightening torque: 41.6 - 60.8 N·m (30.68 - 44.84 lb ft)

3-3 EN

3 - ASSEMBLY

Boom cylinder line installation

*1. *2.

LPIL12DIA0239FB

1

LPIL12DIA0127EB

2

a. b.

Left side holding valve Right side holding valve

Hose assembly Code

3-4 EN

3 - ASSEMBLY

1. Install the stud (3) on the left side holding valve (*1) PL port, then connect the tee (2).

Connect the hose adapter (4) to the right side holding valve (*2) PL port.

Connect the left side holding valve (*1) PL port and right side holding valve (*2) PL port with the assembly hose (81/PI).

LPIL12DIA0102BB

3

LPIL12DIA0342BB

4

2. Install the hose adapter (4) on the left side holding valve (*1) DR port.

Install the stud (3) on the right side holding valve (*2) DR port, and then connect the tee (2).

Connect the left side holding valve (*1) DR port and right side holding valve (*2) DR port with the assembly hose (81/DR).

3-5 EN

3 - ASSEMBLY

3. Install the hose adapter (4) on the left side holding valve (*1) C port.

Install the hose adapter (4) on the right side holding valve (*2) C port.

Connect the left side holding valve (*1) C port and right side holding valve (*2) C port with the hydraulic hose (82).

LPIL12DIA0463BB

5

LPIL12DIA0764BB

6

4. Set the O-ring (83) on the hydraulic hose (80) tip, then install on the right side holding valve (*2) with 2 split flanges (84) and 4 hexagon bolts (85).

Connect the hydraulic hose (80) to the line (*3).

3-6 EN

3 - ASSEMBLY

5. Fasten the assembly hoses (81/PI), (81/DR) and hydraulic hose (80), (82) with the 5 wire bands (86).

LPIL12DIA0633BB

7

3-7 EN

3 - ASSEMBLY

Installation on arm cylinder

LPIL12DIA0213FB

1

1. Remove the bolt ( M12 X 1.75) (*2), and then remove the clamp (*3).

LPIL12DIA0256BB

2

3-8 EN

3 - ASSEMBLY

2. Set the O-ring (3) on the holding valve (2), and then install the holding valve (2) on the arm cylinder (*1) with the 4 hexagon socket head bolts (1).

• Tightening torque: 41.6 - 60.8 N·m (30.68 - 44.84 lb ft) Set the O-ring (3) on the front end of the line assembly (HBCV) (5), then install the line assembly (HBCV) (5) on the holding valve (2) with the 4 hexagon socket head bolts (4).

• Tightening torque: 41.6 - 60.8 N·m (30.68 - 44.84 lb ft)

LPIL12DIA0092BB

3

LPIL12DIA0609BB

4

3. Set the line assembly (HBCV) (5) on the clamp (*3), and then fasten with the bolt ( M12 X 1.75) (*2).

• Tightening torque: 49.0 - 54.0 N·m (36.14 - 39.83 lb ft)

3-9 EN

3 - ASSEMBLY

Arm cylinder line installation

a. b.

Hose assembly Code

LPIL12DIA0189FB

1

LPIL12DIA0228EB

2

*1.

Holding valve

3-10 EN

3 - ASSEMBLY

1. Install the bracket (HBCV) (89) with 2 sems bolts (90).

Fasten the assembly hoses (88/PI) and (88/DR) to the bracket (89) with 2 hose adapters (87).

LPIL12DIA0098AB

3

LPIL12DIA0286AB

4

LPIL12DIA0629AB

5

2. Install the stud (9) and hose adapter (7) on the holding valve (*1) PL port, and then connect the assembly hose (88/PI).

Install the hose adapter (8) on the holding valve (*1) DR port, and then connect the assembly hose (88/DR).

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

4. Fasten the assembly hoses (88/PI) and (88/DR) with 11 wire bands (1). (See the right diagram.)

3-11 EN

3 - ASSEMBLY

Pilot line installation

LPIL12DIA0191FB

1

LPIL12DIA0278FB

2

3-12 EN

3 - ASSEMBLY

a. b.

Hose assembly Code

*1. *2. *3.

Hydraulic oil tank Holding valve (arm) Holding valve (left boom)

*4. *5.

Holding valve (right boom) Control valve

Adjust the hose mouthpiece fitting directions so that all the hydraulic hoses form smooth rounded shapes.

1. Remove the elbow (*8) and pilot line (*9) from the hydraulic oil tank (*1) port (*7), then install the tee (1).

Install the elbow (*8) on the tee (1), and then connect the pilot line (*9).

LPIL12DIA0268BB

3

3-13 EN

3 - ASSEMBLY

2. Connect the hydraulic oil tank (*1) port (*7) and holding valve (*4) DR port with the assembly hose (9/D14).

Fasten the assembly hose (9/D14) with the 3 wire bands (3).

• Tighten the wire bands (3) together with the boom line (*6).

LPIL12DIA0218BB

4

LPIL12DIA0226BB

5

3. Remove the elbow (*8) and pilot line (*9) from the control valve (*5) pc2 port, then install the tee (1).

Install the elbow (*8) on the tee (1), and then connect the pilot line (*9).

3-14 EN

3 - ASSEMBLY

4. Connect the control valve (*5) pc2 port and holding valve (*3) PL port with the assembly hose (2/V6).

Fasten the assembly hose (2/V6) with the 3 wire bands (3).

• Tighten the wire bands (3) together with the boom line (*6).

Fasten the assembly hoses (2/V6) and (9/D14) with the 3 wire bands (3).

• Tighten the wire bands (3) together with the boom line (*6).

Remove the bolt (*10) and set the bracket (12), then fasten with the bolt (*10). Fasten the assembly hoses (2/V6) and (9/D14) with the 4 wire bands (3).

• Tighten the wire bands (3) together with the bracket (12).

LPIL12DIA0097CB

6

3-15 EN

3 - ASSEMBLY

5. Install the tee (11) on the hydraulic oil tank (*1) port (*11).

LPIL12DIA0439BB

7

LPIL12DIA0464AB

8

6. Connect the hydraulic oil tank (*1) port (*8) and HBCV line (DR) (*12) with the assembly hose (9/D13).

3-16 EN

3 - ASSEMBLY

7. Remove the tee (*13) from the control valve (*5) pb9 port, then install the tee (4).

LPIL12DIA0772BB

9

8. Connect the control valve (*5) pb9 port and HBCV line (PL) (*14) with the assembly hose (2/A6). Fasten the bracket (7) with the 2 sems bolts (8).

Fasten the assembly hoses (2/A6) and (9/D13) at 3 locations with 1 clamp with band (5) each and 1 special bolt (6) each.

• Tightening torque: 23.5 - 35.3 N·m (17.33 - 26.04 lb ft) Adjust the hose lengths so that the lengths from the assembly hose (2/A6) and (9/D13) ends to the clamp (5) are the dimensions shown below: Hose ID A6 D13

Dimension (L) 650 mm (25.59 in) 650 mm (25.59 in)

LPIL12DIA0796BB

10

3-17 EN

3 - ASSEMBLY

9. Fasten the assembly hoses (2/A6) and (9/D13) with the wire band (10).

• Tighten the wire bands (3) together with the pilot line (*15).

LPIL12DIA0624BB

11

3-18 EN

3 - ASSEMBLY

Installation of housing cover

SMIL14II00850FB

1

1. Install the rubber cushion ( (39) ) on the cover (16).

Install the cover (16) on the frame (*2) with the 2 bolts (*1).

3-19 EN

3 - ASSEMBLY

3-20 EN

Index ###_Index_###

A Arm cylinder line installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 B Boom cylinder line installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4

H HBCV Installation on boom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1

I Installation of housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Installation on arm cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 K Kit content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

P Pilot line installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

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