CNH CX80C Midi Excavator 2nd Option Line Proportional Control Kit Installation Instructions Manual

INSTALLATION INSTRUCTIONS

KG1AP062-00

2ND OPTION LINE PROPORTIONAL CONTROL KIT

APPROXIMATE INSTALLATION TIME: 20.0 hours

Tor - 47683012 Issue date March 2014 EN

KG1AP062-00 - 2ND OPTION LINE PROPORTIONAL CONTROL KIT CASE CONSTRUCTION CX80C

Tor - 47683012 Issue date March 2014 EN

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

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

3 ASSEMBLY 2ND OPTION LINE PROPORTIONAL CONTROL Boom line installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Upper main line installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Pilot line installation - Proportional control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Harness installation - proportion control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Removal and installation of control lever (left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Attachment of plate 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 (left) (Refer to 3-21) Item 1

Description Knob (left) proportional control

Quantity 1

Part Reference KHJ28540

Quantity 6 1 2 1 3 2 5 1 2 1 1

Part Reference KAR0017 KAJ19310 KHJ0641 KHJ1215 KHR2581 KHJ1214 KHH0142 KAJ18060 105R010Y016R KHJ0342 KHJ13900

2nd double-acting main circuit (Refer to 3-5) Item 1 2 3 4 5 6 7 8 9 10 11

Description Wire band (L = 380) Assembly hose Elbow Special bolt ( M8 X 25) Clamp with band ( M8) Special bolt ( M8 X 20) Wire band (L = 250) Bracket Sems bolt ( M10 X 16) Elbow ( G3/8) Tee ( G1/4 x G3/8)

2nd double-acting pilot circuit proportional control (Refer to 3-11) Item 1 2 3 4 5 6 9 10 11 12 13 14 16

Description Assembly hose Hose adapter ( G1/4) Elbow ( G1/4) Reducing valve Hose adapter ( G1/4) Pressure switch Stud with filter ( G1/4) Assembly hose Tee ( G1/4) Sems bolt ( M8 X 20) Elbow ( G1/4) Stud ( G1/4) Tee ( G1/4)

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

Part Reference KAJ20140 KNJ0758 KHJ0341 MFJ71500 KAJ3807 KHR21490 KHJ25100 KAJ17300 KHJ2773 105R008Y020R KHJ0348 KHJ13640 KHJ0869

Quantity

Part Reference

1

KHR13370

5 3 3 6 6 2

KHH0142 KHR0319 145N006S008B 105R008Y016R KHR1317 KHR10220

Electrical part (Refer to 3-16) Item 1 2 3 4 6 7 8

Description Option (proportional control + proportional control) wire harness Wire band (L = 250) Mount clamp Phillips pan head screw Sems bolt ( M8 X 16) Clip Mount clamp

1-1 EN

1 - KIT CONTENT

Plate (Refer to 3-25) Item 1

Description Operation label (proportional control)

Quantity 1

Part Reference KHP21150

Quantity 4 2 12 16 4 2 2 1 4 1

Part Reference KAV1627 KAV13750 102R012Y045R KHN0296 KAV1844 KAV19050 105R012Y030R KAV13800 102R012Y070R KAV16240

Quantity 1 1 1 3

Part Reference KAV19500 KAV19490 KAV19520 KAV19510

Clamp (Refer to 3-1) Item 1 2 3 4 5 6 7 8 9 11

Description Pipe clamp Seating High-strength bolt ( M12 X 45) High-strength washer ( M12) Pipe clamp Seating Sems bolt ( M12 X 30) Plate High-strength bolt ( M12 X 70) Seating

Boom line (Refer to 3-1) Item 12 13 14 15

Description Line Line Line Line

assembly (right) assembly (left) assembly (drain) assembly

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, 27 mm) • Box wrenches ( 13 mm, 17 mm, 19 mm, 22 mm, 27 mm) • 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 out 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 2ND OPTION LINE PROPORTIONAL CONTROL

Boom line installation

SMIL14II00041FB

1

3-1 EN

3 - ASSEMBLY

Line assemblies (15) 1. Set the line assemblies (15) on the boom.

SMIL14II00042BB

2

SMIL14II00043AB

3

2. Install the seating (11) with the high-strength bolt (9) and high-strength washer (4).

Set the pipe clamp (1) on the 2 line assemblies (15), and then install with the high-strength bolt (3) and highstrength washer (4).

Set the pipe clamp (5) on the line assembly (15), and then install with the high-strength bolt (3) and highstrength washer (4).

• Fasten the pipe clamps (1) and (5) at a position 50 mm (1.97 in) from the rear end of the line assembly (15).

Install with the high-strength bolt (9) and high-strength washer (4).

3-2 EN

3 - ASSEMBLY

Line assembly (left) (13), line assembly (drain) (14), and line assembly (right) (12) 1. Set the line assembly (left) (13), line assembly (drain) (14), and line assembly (right) (12) on the boom, and then connect with the 3 line assemblies (15).

SMIL14II00044BB

4

SMIL14II00045AB

5

2. Install the plate (8) with the high-strength bolt (9) and high-strength washer (4).

Set the pipe clamp (1) on the line assembly (left) (13) and line assembly (drain) (14), and then install with the high-strength bolt (3) and high-strength washer (4).

Set the pipe clamp (5) on the line assembly (right) (12), and then install with the high-strength bolt (3) and highstrength washer (4).

3-3 EN

3 - ASSEMBLY

3. Install the seating (2) with 2 high-strength bolts (3) and 2 high-strength washers (4).

Set the pipe clamp (1) on the line assembly (left) (13) and line assembly (drain) (14), and then install with the high-strength bolt (3) and high-strength washer (4).

• Fasten the pipe clamp (1) at a position 240 mm (9.45 in) from the front ends of the line assembly (left) (13) and the line assembly (drain) (14).

Install the seating (2) with 2 high-strength bolts (3) and 2 high-strength washers (4).

Set the pipe clamp (5) on the line assembly (right) (12), and then install with the high-strength bolt (3) and highstrength washer (4).

SMIL14II00046AB

6

SMIL14II00047AB

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• Fasten the pipe clamp (5) at a position 240 mm (9.45 in) from the front ends of the line assembly (right) (12).

4. Install the seating (6) with the sems bolts (7).

Set the pipe clamp (1) on the line assembly (left) (13) and line assembly (drain) (14), and then install with the high-strength bolt (3) and high-strength washer (4).

Install the seating (6) with the sems bolts (7).

Set the pipe clamp (5) on the line assembly (right) (12), and then install with the high-strength bolt (3) and highstrength washer (4).

3-4 EN

3 - ASSEMBLY

Upper main line installation

SMIL14II00048FB

1

1. Install the elbow (3) on the control valve (*1) A12 port and connect the assembly hose (2/Y6).

SMIL14II00049BB

2

3-5 EN

3 - ASSEMBLY

2. Pass the assembly hose (2/Y6) through the main unit frame to the front end of the swing bracket (*2).

SMIL14II00050AB

3

SMIL14II00051BB

4

3. Connect the assembly hose (2/Y6) to the line (left) (*4).

• Check that the vinyl tube side is connected.

3-6 EN

3 - ASSEMBLY

4. Install the elbow (3) on the control valve (*1) B12 port and connect the assembly hose (2/Y7).

SMIL14II00052BB

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SMIL14II00050AB

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5. Pass the assembly hose (2/Y7) through the main unit frame to the front end of the swing bracket (*2).

3-7 EN

3 - ASSEMBLY

6. Connect the assembly hose (2/Y7) to the line (right) (*5).

• Check that the vinyl tube side is connected.

SMIL14II00053BB

7

SMIL14II00054BB

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7. Install the elbow (10) or tee (11) (when the circuit has an HBCV) on the return and oil cooler line (*6) and connect the assembly hose (2/Y8).

Fasten the assembly hoses (2/Y6) (2/Y7) (2/Y8) and option 1 line (*7) together with the wire band (7).

Fasten the assembly hoses (2/Y6) (2/Y7) (2/Y8) with the clamp with band (5) and special bolt (6).

• Bolt tightening torque: 23.5 - 35.3 N·m (17.3 - 26 lb ft) • Align the position markers on the assembly hoses (2/Y6) (2/Y7) (2/Y8).

Fasten the assembly hoses (2/Y6) (2/Y7) (2/Y8) and option 1 line (*7) together with the wire band (1).

Fasten the assembly hoses (2/Y6) (2/Y7) (2/Y8) with 1 bracket (8) and 2 sems bolts (9).

3-8 EN

3 - ASSEMBLY

8. Fasten the assembly hoses (2/Y6) (2/Y7) (2/Y8) with the clamp with band (5) and special bolt (4).

• Bolt tightening torque: 23.5 - 35.3 N·m (17.3 - 26 lb ft)

SMIL14II00055BB

9

9. Fasten the assembly hoses (2/Y6) (2/Y7) (2/Y8) with the clamp with band (5) and special bolt (6).

• Bolt tightening torque: 23.5 - 35.3 N·m (17.3 - 26 lb ft) • Align the position markers on the assembly hoses (2/Y6) (2/Y7) (2/Y8).

Fasten the assembly hoses (2/Y6) (2/Y7) (2/Y8), boom line (*8), and option 1 line (*7) together with the wire band (1).

Fasten the assembly hoses (2/Y6) (2/Y7) (2/Y8) and boom line (*8) together with the wire band (1).

• Set the cut surface of the wire band (1) on the tank side.

Fasten the assembly hoses (2/Y6) (2/Y7) (2/Y8) with the wire band (7).

SMIL14II00056BB

10

3-9 EN

3 - ASSEMBLY

10. Fasten the assembly hoses (2/Y6) (2/Y7) (2/Y8) and option 1 line (*7) together with 3 wire bands (1).

When there is no option 1 line (*7), fasten together with the arm line (*9).

Fasten the assembly hoses (2/Y6) (2/Y7) (2/Y8) and vinyl tubes on each hose with 1 wire band (7) each.

SMIL14II00057BB

11

3-10 EN

3 - ASSEMBLY

Pilot line installation - Proportional control

SMIL14II00058FB

1

SMIL14II00059FB

2

3-11 EN

3 - ASSEMBLY

a. b. *1.

Hose assembly Code Cushion valve

*2. *3.

Manifold Control valve

When installing the hydraulic hoses, adjust the hose fitting directions so that they form smooth rounded shapes.

1. Install the reducing valve (4) on the bracket with 2 sems bolts (12).

Install the hose adapter (2) on the reducing valve (4) T port.

• Joint tightening torque: 25.4 - 31.4 N·m (18.7 23.2 lb ft) Install the tee (11) or elbow (13) on the cushion valve (*1) T port.

Connect the reducing valve (4) T port and cushion valve (*1) T port with the assembly hose (1/T6).

SMIL14II00060BB

3

3-12 EN

3 - ASSEMBLY

2. Install the stud with filter (9) and hose adapter (2) on the reducing valve (4) P port.

• Joint tightening torque: 25.4 - 31.4 N·m (18.7 23.2 lb ft) Install the tee (16) on the manifold (*2) P5 port.

Connect the reducing valve (4) P port and manifold (*2) P5 port with the assembly hose (10/P6).

SMIL14II00061BB

4

SMIL14II00062BB

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3. Install the hose adapter (5) on the reducing valve (4) A1 port and connect the pressure switch (6).

• Joint tightening torque: 25.4 - 31.4 N·m (18.7 23.2 lb ft)

3-13 EN

3 - ASSEMBLY

4. Install the stud (14) on the control valve (*3) Pb12 port and connect the elbow (13).

Connect the reducing valve (4) A1 port and control valve (*3) Pb12 port with the assembly hose (1/Y7).

SMIL14II00063BB

6

SMIL14II00064BB

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5. Install the hose adapter (5) on the reducing valve (4) A2 port and connect the pressure switch (6).

• Joint tightening torque: 25.4 - 31.4 N·m (18.7 23.2 lb ft)

3-14 EN

3 - ASSEMBLY

6. Install the elbow (3) on the control valve (*3) Pa12.

Connect the reducing valve (4) A2 port and control valve (*3) Pa12 port with the assembly hose (1/Y6).

SMIL14II00065BB

8

3-15 EN

3 - ASSEMBLY

Harness installation - proportion control

SMIL14II00066FB

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SMIL14II00067FB

2

3-16 EN

3 - ASSEMBLY

* The quantity of parts varies depending on the specifications.

1. For 2nd option 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 (1) with 1 clip (7) each and 1 sems bolt (6) each.

Fasten the wire harness (1) with the mount clamp (8) and wire band (2).

SMIL14II00068BB

3

SMIL14II00069BB

4

2nd

2. When there is no option circuit, fasten the 2 couplers on the wire harness (1) with 1 clip (7) each and 1 sems bolt (6) each.

Fasten the wire harness (1) with the mount clamp (8) and wire band (2).

3-17 EN

3 - ASSEMBLY

3. For breaker circuit, fasten the 2 couplers on the wire harness (1) with 1 clip (7) each and 1 sems bolt (6) each.

Fasten the wire harness (1) with the mount clamp (8) and wire band (2).

SMIL14II00070AB

5

SMIL14II00071AB

6

SMIL14II00072AB

7

SMIL14II00073AB

8

4. For multi-purpose circuit, connect the wire harness (1) and the solenoid valve (*4) 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 (1) with 1 clip (7) each and 1 sems bolt (6) each.

Fasten the wire harness (1) with the mount clamp (8) and wire band (2).

5. For double-acting circuit, connect the wire harness (1) and the solenoid valve (*4) 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 (1) with 1 clip (7) each and 1 sems bolt (6) each.

Fasten the wire harness (1) with the mount clamp (8) and wire band (2).

6. When there is no 1st option circuit, fasten the 2 couplers on the wire harness (1) with 1 clip (7) each and 1 sems bolt (6) each.

Fasten the wire harness (1) coupler with the wire band (2).

3-18 EN

3 - ASSEMBLY

7. For double-acting circuit and multi-purpose 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 (1) with 1 clip (7) each and 1 sems bolt (6) each.

SMIL14II00074BB

9

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

Fasten the wire harness (1) at 3 locations with 1 wire band (2) each, 1 mount clamp (3) each, and 1 Phillips pan head screw (4) each.

SMIL14II00075BB

10

3-19 EN

3 - ASSEMBLY

9. 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 (*5).

10. When the kit comes with screw caps (5), install them on the floor. (See figure 2.)

SMIL14II00076BB

11

3-20 EN

3 - ASSEMBLY

Removal and installation of control lever (left) 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.

3-21 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).

3-22 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).

3-23 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).

3-24 EN

3 - ASSEMBLY

Attachment of plate inside cab

SMIL14II00091GB

1

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

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

3-25 EN

3 - ASSEMBLY

3-26 EN

Index ###_Index_###

A Attachment of plate inside cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 B Boom line installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1

H Harness installation - proportion control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 K Kit content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

P Pilot line installation - Proportional control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-11 2-1

R Removal and installation of control lever (left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 U Upper main line installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5

EN

SERVICE - Technical Publications & Tools

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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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