CNH CX300C Crawler Excavator Hydraulic Hammer Circuit Installation Instructions Manual 47435604

INSTALLATION INSTRUCTIONS

KG1BP132-00

HYDRAULIC HAMMER CIRCUIT

APPROXIMATE INSTALLATION TIME: 28 hours

Le - 47435604 3006-00NA-112 Issue date September 2012 EN

KG1BP132-00 - HYDRAULIC HAMMER CIRCUIT CASE CONSTRUCTION CX300C

Le - 47435604 3006-00NA-112 Issue date September 2012 EN

Contents 1 KIT CONTENT General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

2 PRE-ASSEMBLY PREPARING FOR ASSEMBLY Hydraulic systems - Depressurising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

3 ASSEMBLY Hydraulic Hammer Hammer system lines - Install (On boom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Hammer system lines - Install (On upperstructure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Command valve Hammer - Install (Remote Control Valve) . . . . . . . . . . . . . . . . . . . . . . . 3-20 Hammer system lines - Install (Pilot line) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Hammer electric system - Install (Harness) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 Hydraulic fluid filter restriction sensor - Install (filter clog warning) . . . . . . . . . . . . . . . 3-31 Cab interior trim and panels - Transform (Processing for Adding Floor Mat) . . . . . 3-33 Safety signs or informational decals - Install (Inside cab) . . . . . . . . . . . . . . . . . . . . . . . . 3-34

EN

1 - KIT CONTENT

1 - KIT CONTENT General specification CX300C NA

Service Valve (refer to 3-20) Code 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Part Number KHJ13850 KHJ24800 150604A1 165404A1 166052A1 KHJ24720 163782A1 KHJ24740 KHJ10701 108R010Y016R KHJ10711 KHJ24780 KHJ10721 159500A1 157740A1

Description Option pedal Hexagon socket head bolt High-strength washer (KHJ0183) Hexagon socket head bolt (KHJ1104) Sems bolt (105R010Y025R) Remote control valve Pedal plastic cover (KHP0912) Option right pedal bracket Lock lever Hexagon socket head bolt Lock bracket Option pedal bracket Compression spring Plain washer (KHN0420) High-strength nut (KHJ0091)

Remarks

Qty 1 2 6 2 2 1 1 1 1 2 1 1 1 1 1

M10x25 M10 M10x20 M10x25

M10x16

M8 M8

Breaker Main Circuit (refer to 3-12) Part Number Code 1 150124A1 2 862-14050 3 KBJ11790 4 164450A1 5 KHJ11370 6 KBJ12510 7 KHJ1361 8 151655A1 9 KBJ12260 10 KRJ16400 11 157586A1 12 KHJ25900 13 KHJ1349 14 KBJ16300 15 166352A1 16 KBJ13790 17 KHJ2680 18 KBJ11860 19 KBJ15230 20 KHJ15050 21 KRJ11470 22 862-10030 23 153459A1 24 155211A1

Description Split flange (KTJ0029) Hexagon socket head bolt (108R014Y050R) Hydraulic hose O-ring (LBQ5222) Elbow Hydraulic hose O-ring Hose adapter (KNJ0606) Hydraulic hose Manifold Elbow (KHJ0351) Socket Hose adapter Bracket Sems bolt (105R012Y030R) Hydraulic hose Hose clamp Bracket Bracket Relief valve Bracket Hexagon socket head bolt (108R010Y030R) Split flange (KRJ2682) O-ring (LBQ6219)

Qty 4 8 2 2 1 1 3 2 1 1 2 1 2 1 15 1 1 1 1 1 1 4 2 1

Remarks G1-1/4 M14x50

G1

G3/4

M12x30

M10x30 G1

Breaker Pilot Circuit (refer to 3-22 and 3-28) 2 3 4 5

KHJ25100 150913A1 KBJ16640 KRJ12470

1 2 1 1

Stud Elbow (KHJ0341) Assembly hose Assembly hose

G1/4 G1/4

1-4 EN

1 - KIT CONTENT

6 9 12 13 14 15

167666A1 150496A1 KHR21490 161841A1 159002A1 152127A1

Hose adapter (KAJ3807) Wire band (KHH0142) Pressure switch Nipple (CNA0584) Plug (KHJ0363) Hose adapter (KNJ0758)

1 1 1 1 2 2

Description Multi-purpose + 2nd option wire harness Elbow (KHJ0341) Mount clamp (KHR0319) Phillips pan head screw (145T006S008R) Wire band (KHH0142) Clip (KHR1317) Sems bolt (105R008Y016R)

1 2 7 7 9 4 4

G1/4 L=250 G1/4 G1/4 G1/4

Plug (refer to 3-22 and 3-28) Code 1 3 7 8 9 10 11

Part Number KHR28600 150913A1 150860A1 840-168 150496A1 158962A1 166345A1

Remarks

Qty G1/4

M6x8 L=250 M8x16

Indicator (refer to 3-31) Code 1 2 3 4 5 6 8

Part Number 150496A1 KHR32870 KHJ12530 KHR33100 KHR2584 167320A1 159002A1

Description Wire band (KHH0142) Pressure sensor Tee Indicator wire harness Clamp with band Special bolt (KHJ1214) Plug (KHJ0363)

3 1 1 1 2 1 1

Description Foot control operation label (ISO)

1

Description Pipe clamp Sems bolt (105R012Y030R) Pipe clamp Pipe clamp

4 16 2 8

Description Line assembly (right) Line assembly (left) Plug (BRJ1286) Line assembly (right) Line assembly (left) Hexagon socket head bolt (108R014Y050R) Split flange (KTJ0029) O-ring (LBQ5222)

1 1 2 1 1 8 4 2

Qty

Remarks L=250 G1/4 G1/4xG3/8xG1/4 M8 M8x25 G1/4

Nameplate (refer to 3-34) Code 12

Part Number KHP1485

Qty

Remarks

Qty

Remarks

Clamp (refer to 3-8) Code 1 2 4 5

Part Number KHV11060 166352A1 KHV11070 KHV11050

M12x30

Line (refer to 3-8) Code 7 8 9 10 11 12 13 14

Part Number KBV18930 KBV18920 152924A1 KBV18910 KBV18900 862-14050 150124A1 164450A1

Remarks

Qty

G3/4

M14x50 G1-1/4

1-5 EN

2 - PRE-ASSEMBLY

2 - PRE-ASSEMBLY PREPARING FOR ASSEMBLY

Hydraulic systems - Depressurising CX300C NA

NOTE: An "*" in this document indicates that the part is mounted on the actual machine. (i.e. (*n)).

Items to prepare •

Wrenches 13 mm (0.51 17 mm (0.67 19 mm (0.75 36 mm (1.42 41 mm (1.61 46 mm (1.81 50 mm (1.96

in) in) in) in) in)) in)) in))

•

Hexagon wrenches 8 mm (0.31 in) 12 mm (0.47 in)

•

Phillips screwdriver (No.3)

•

Cutters, scissors

•

Rag

NOTE: For hose and electrical connexions, refer to the hydraulic and electrical posters included in the Service Manual.

NOTE: Special torque settings are shown in these instructions.

If a torque setting is not shown, use the standard torque settings in the Service Manual.

NOTE: Dimensions on figures are shown in mm.

NOTE: This arrow (shown in the illustrations) indicates the Front side of the machine.

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 out stroke end, lower the boom, and touch the arm top to the ground.

7LNRSN-005

1

2-6 EN

2 - PRE-ASSEMBLY

2.

3.

4.

Switch the ignition key (a) Off, check that the engine has stopped, then switch the ignition key (a) On again. (Do not start the engine.)

7LNRSN-006

2

7LNRSN-007

3

7LNRSN-008

4

Bleed out the pressure inside the circuit.

•

Flip the lever (c) forward, 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.

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.

2-7 EN

3 - ASSEMBLY

3 - ASSEMBLY Hydraulic Hammer

Hammer system lines - Install (On boom) CX300C NA

KYOXIM-006

1

3-8 EN

3 - ASSEMBLY

Line assemblies (10) (11) 1.

2.

Set the line assembly (left) (11) on the boom.

LRUPUY-001

2

F93268AA

3

Sandwich the line assembly (left) (11) at 2 locations with 2 pipe clamps (5) each, and fasten with 2 sems bolts (2) each.

Fasten the rear pipe clamp (5) at a position 287 mm (11.3 in) from the rear end of the line assembly (left) (11).

Fasten the front pipe clamp (5) so that the distance between the front end of the line assembly (left) (11) and *a is 394 mm (15.5 in).

When installing together with HBCV, install 1 sems bolt (*1) each.

The diagram below shows the HBCV specification.

3-9 EN

3 - ASSEMBLY

3.

Install the plug (9) on the line assembly (left) (11).

4.

Install the line assembly (right) (10) in the same way as the line assembly (left) (11).

LRUPUY-003

4

3RMTAZ-001

5

3RMTAZ-002

6

3RMTAZ-004

7

Line assemblies (7) (8) 5.

6.

7.

Set the line assembly (left) (8).

Fasten the line assembly (left) (8) with the 1 pipe clamps (4) and the 2 sems bolts (2).

Fasten the pipe clamp (4) at a position 130 mm (5.1 in) from the end of the line assembly (left) (8).

After setting the O-ring (14) on the end of the line assembly (left) (8), connect the line assembly (left) (11) with the 2 split flanges (13) and the 4 hexagon socket head bolts (12).

3-10 EN

3 - ASSEMBLY

8.

Fasten the line assembly (left) (8) with the 1 pipe clamp (2) and the 2 sems bolts (2).

3RMTAZ-003

9.

8

Install the line assembly (right) (7) in the same way as the line assembly (left) (8).

3-11 EN

3 - ASSEMBLY

Hammer system lines - Install (On upperstructure) CX300C NA

JKZMR4-041

1

Main line installation

3-12 EN

3 - ASSEMBLY

Left side 1.

2.

Install the bracket (21) on the frame with the 4 sems bolts (15).

Install the relief valve (20) on the bracket (21) with the 2 sems bolts (15).

Adjust the pressure setting for the relief valve (20) to match the type of attachment used.

MD2X3G-026

2

MD2X3G-027

3

Install the elbow (5) on the relief valve (20) A port.

Set the O-ring (7) on the elbow (5) and connect the hydraulic hose (6).

Tightening torque : 184 - 226 N·m (1628.5 - 2000.3 lb in).

3-13 EN

3 - ASSEMBLY

3.

4.

Set the O-ring (24) on the control valve (*1) A2 port, and install the hydraulic hose (6) with the 2 split flanges (23) and the 4 hexagon socket head bolts (22).

Tightening torque : 37.2 - 47.2 N·m (329.2 - 417.8 lb in).

MD2X3G-028

4

MD2X3G-029

5

Install the hose adapter (13) on the relief valve (20) B port.

Set the O-ring (7) on the hose adapter (13) and install the hydraulic hose (3).

Tightening torque : 184 - 226 N·m (1628.5 - 2000.3 lb in).

3-14 EN

3 - ASSEMBLY

5.

Set the O-ring (4) on the hydraulic hose (3), then connect to the line assembly (left) (*3) with 2 split flanges (1) and 4 hexagon bolts (2).

Tightening torque : 85.2 - 101.2 N·m (754.1 - 895.7 lb in).

MD2X3G-030

6

BSJYOQ-056

7

Right side 6.

Install the bracket (14) on the frame with the 4 sems bolts (15).

3-15 EN

3 - ASSEMBLY

7.

8.

Install the manifold (10) on the bracket (14) with the 2 sems bolts (15).

BSJYOQ-057

8

BSJYOQ-058

9

Install the hose adapter (8) on the manifold (10) hydraulic oil tank (*2) side.

Connect the hydraulic hose (9) to the hose adapter (8).

3-16 EN

3 - ASSEMBLY

9.

10.

Install the hose adapter (8) on the hydraulic oil tank (*2).

Connect the hydraulic hose (9) to the hose adapter (8).

BSJYOQ-059

10

BSJYOQ-060

11

Install the bracket (19) on the housing frame with the 2 sems bolts (15).

Set the hose clamp (17) on the hydraulic hose (9), and then install the bracket (18) on the bracket (19) with the sems bolt (15).

3-17 EN

3 - ASSEMBLY

11.

12.

Install the elbow (11) on the relief valve (20) T port.

Install the elbow (11) on the manifold (10) relief valve side.

Connect the relief valve (20) T port and manifold (10) relief valve side with the hydraulic hose (16).

BSJYOQ-061

12

BSJYOQ-062

13

Install the socket (12) on the manifold (10) line assembly (right) (*4) side, and connect the hose adapter (13).

Set the O-ring (7) on the hose adapter (13) and connect the hydraulic hose (3).

Tightening torque : 184 - 226 N·m (1628.5 - 2000.3 lb in).

3-18 EN

3 - ASSEMBLY

13.

Set the O-ring (4) on the hydraulic hose (3), then connect to the line assembly (*4) with 2 split flanges (1) and 4 hexagon bolts (2).

Tightening torque : 85.2 - 101.2 N·m (754.1 - 895.7 lb in).

BSJYOQ-063

14

3-19 EN

3 - ASSEMBLY

Command valve Hammer - Install (Remote Control Valve) CX300C NA

OW4Z1S-006

1

Service Valve Installation 1.

Remove the floor mats from the cab.

2.

Install the remote control valve (14) on the front right section of the floor with the 2 sems bolts (13).

Install the option right pedal bracket (16) on the remote control valve (14) with the 2 hexagon socket head bolts (12) and 2 high-strength washers (11).

OW4Z1S-007

2

3-20 EN

3 - ASSEMBLY

3.

4.

Set the lock lever (17) and the compression spring (21) on the lock bracket (19), and then fasten with the high-strength nut (23) and plain washer (22).

Fit the lock lever (17) onto the slot of the option right pedal bracket (16), and then install the lock bracket (19) on the floor with the 2 hexagon socket head bolts (18) and 2 high-strength washers (11).

OW4Z1S-008

3

OW4Z1S-009

4

Install the option pedal bracket (20) and option pedal (9) with the 2 hexagon socket head bolts (10) and 2 high-strength washers (11).

Cover the option pedal (9) with the pedal plastic cover (15).

3-21 EN

3 - ASSEMBLY

Hammer system lines - Install (Pilot line) CX300C NA

CZPI3R-212

1

Pilot line installation

3-22 EN

3 - ASSEMBLY

CZPI3R-213

2

Pilot line installation under the floor

3-23 EN

3 - ASSEMBLY

CZPI3R-214

3

Hose connection diagram (*1) (*1)a (*1)b (*1)c (*1)d (*1)e (12) 1.

Remote control valve Line name Pedal front operation Pedal rear operation Pressure Return Pressure switch

(4) (5) (*2) (*3) (f) (g)

Assembly hose Assembly hose Manifold Control valve Hose part number Hose part name

Install the hose adapter (15) on the remote control valve (*1) T port.

CZPI3R-215

4

3-24 EN

3 - ASSEMBLY

2.

3.

4.

5.

Install the elbow (3) at the manifold (*2) T5 port.

Connect the remote control valve (*1) T port and manifold (*2) T5 port with the assembly hose (4/T5).

CZPI3R-216

5

CZPI3R-217

6

CZPI3R-218

7

CZPI3R-219

8

Install the plug (14) on the remote control valve (*1) C1 port.

Install the nipple (13) on the remote control valve (*1) P port.

Install the elbow (3) at the manifold (*2) P5 port.

Connect the remote control valve (*1) P port and manifold (*2) P5 port with the assembly hose (4/P5).

Install the plug (14) on the remote control valve (*1) A port.

Install the hose adapter (15) on the remote control valve (*1) B port.

3-25 EN

3 - ASSEMBLY

6.

Install the stud (2) on the control valve (*3) pa2 port and connect the elbow (3).

Connect the remote control valve (*1) B port and control valve (*3) pa2 port with the assembly hose (4/Y1).

CZPI3R-220

7.

9

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

Install the hose adapter (6) on the control valve (*3) DR4 port.

Connect the control valve (*3) pb2 port and DR4 port with the assembly hose (5/Y2).

CZPI3R-221

10

3-26 EN

3 - ASSEMBLY

8.

Fasten the assembly hoses (4/Y1) (4/P5) (4/T5) that come out from the remote control valve (*1) at 3 locations with 1 mount clamp (7) each, 1 Phillips pan head screw (8) each, and 1 wire band (9) each.

Fasten the assembly hoses (4/P5) (4/T5) that come out from the remote control valve (*1) with the wire bands (9).

Fasten the assembly hoses (4/P5) (4/T5) together with the pilot control line (*4).

CZPI3R-222

11

3-27 EN

3 - ASSEMBLY

Hammer electric system - Install (Harness) CX300C NA

BOZQCU-070

1

Harness installation under the floor 1.

Install the pressure switch (12) on the remote control valve (*1) C2 port.

BOZQCU-071

2

3-28 EN

3 - ASSEMBLY

2.

3.

Route the wire harness (1) and connect to the pressure switch (12).

Fasten the wire harness (1) at 4 locations with 1 mount clamp (7) each, 1 Phillips pan head screw (8) each, and 1 wire band (9) each.

BOZQCU-072

3

BOZQCU-073

4

Fasten the pressure switch (12) harness with the clip (10) and sems bolt (11).

3-29 EN

3 - ASSEMBLY

4.

5.

Fasten the 3 couplers along the wire harness (1) with 1 clip (10) each and 1 sems bolt (11) each.

Be careful to fasten the coupler (red tape) (*6) and the coupler (blue tape) (*7) in the correct position.

BOZQCU-074

5

BOZQCU-075

6

Extend the wire harness (1) to the floor side from under the cab and connect to the cab main harness (*5).

Fasten the wire harness (1) with the 2 wire bands (9).

Tighten the wire harness (1) together with the frame main harness (*8).

3-30 EN

3 - ASSEMBLY

Hydraulic fluid filter restriction sensor - Install (filter clog warning) CX300C NA

3AC125B0

1.

2.

1

Remove the elbow (*2) and the pilot P and T lines (D2) (*3) from the hydraulic oil tank (*1), and then install the tee (3).

Install the pressure sensor (2) on the tee (3).

80FC0640

2

818F1252

3

Install the elbow (*2) on the tee (3), and then connect the pilot P and T lines D2 (*3) Install the indicator wire harness (4) on the pressure sensor (2), and then fasten with the wire band (1).

3-31 EN

3 - ASSEMBLY

3.

4.

Install the indicator wire harness (4) on the frame main wire harness (*4), and then fasten with the clamp with band (5) and bolt (6).

Install the plug (8) on the hydraulic oil tank (*1).

D24CEC84

4

EA841D9B

5

Fasten the indicator wire harness (4) with 2 wire bands (1).

Tighten 1 of the 2 wire bands (1) together with the pilot P and T lines (*5).

Adjust the length of the indicator wire harness (4) and fasten it at the position (*6).

3-32 EN

3 - ASSEMBLY

Cab interior trim and panels - Transform (Processing for Adding Floor Mat) CX300C NA

VOTOTR-001

1

Floor mat 1.

Remove the floor mat from the cab.

2.

Spread out the floor mat on a flat platform and mark the dimensional positions.

3.

Use cutters or scissors to cut slits (*1).

4.

Set the cut floor mat in the cab.

3-33 EN

3 - ASSEMBLY

Safety signs or informational decals - Install (Inside cab) CX300C NA

ORS6Q1-023

1.

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

2.

Attach the foot control operation label (ISO) (12).

1

3-34 EN

3 - ASSEMBLY

3-35 EN

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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.

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