CNH Double-acting circuit kit (proportional control) CX160D Crawler excavator Instructions Manual

INSTALLATION INSTRUCTIONS

KG0LP424-00

DOUBLE-ACTING CIRCUIT KIT (PROPORTIONAL CONTROL)

APPROXIMATE INSTALLATION TIME: 25.0 hours

San - 47891692 Issue date July 2015 EN

KG0LP424-00 - DOUBLE-ACTING CIRCUIT KIT (PROPORTIONAL CONTROL) CASE CONSTRUCTION CX160D

San - 47891692 Issue date July 2015 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) Boom line installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Upper main line installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Pilot line installation - Proportional control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Harness installation - Proportional control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Control lever installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Port relief valve installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 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 (right) (Refer to 3-20) Item 1

Description Knob (right-hand) proportional control

Quantity 1

Part Reference KHJ28550

Quantity 14 2 3 2 6 1 1 1 1 1 2 1 2 1 1 2 1 1 1 4 8 2

Part Reference 105R012Y030R KRJ12170 KHJ1941 KLJ11690 KHJ1360 KRJ11470 KHJ16290 KLJ14870 KRJ16050 KNJ18430 KLJ14740 KRH10210 105R010Y030R KLJ14860 KNJ12880 KHJ2587 KHJ14710 KHJ14720 KHJ14690 KRJ2681 108R010Y030R KHJ0913

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

Part Reference KLJ14900 KHJ2248 KHJ2198 KHJ11500 KHH0142 KHJ28810 KNJ23160 KHJ2163 KHJ2246 KHJ2089 KHJ2195 KNJ0758 KRJ3557 102R006Y016R 183-106VR KHJ30520 105R008Y016R 105R010Y020R KHJ0894

Double-acting main circuit proportional control (Refer to 3-5) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 21 22 23

Description Sems bolt M12x30 Manifold Hose adapter Hydraulic hose O-ring Bracket Elbow Hydraulic hose Bracket Bracket Hose clamp Plate Sems bolt M10x30 Hydraulic hose Hydraulic hose O-ring Hose adapter Check valve Elbow G1/2 Split flange Hexagon socket head bolt M10x30 O-ring

Double-acting pilot circuit proportional control (Refer to 3-11) Item 2 2-1 2-2 2-3 3 4 5 5-1 5-2 5-3 5-4 6 7 8 9 11 13 15 16

Description Assembly hose Nylon hose Nylon hose Nylon hose Wire band L = 250 Long elbow G1/4 Assembly hose 5-1 - 5-4 Nylon hose Nylon hose Nylon hose Nylon hose Hose adapter G1/4 Solenoid valve High-strength bolt M6x16 Spring washer M6 Bracket Sems bolt M8 x 16 Sems bolt M10x20 Stud G1/4 1-1

EN

1 - KIT CONTENT

Item 17 18 19 20 21 22 23 24 25 26 27 28 29

Description

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

Part Reference CNA0584 KHJ0869 KHJ28770 KHR0319 145N006S008R KAR0017 KHH0143 KHJ28580 KHR2581 KAJ3807 KHR2584 KHR26940 MFJ71500

Description

Quantity 1 8 3 3

Part Reference KHR39501 KHH0142 KHR1957 KHR1253

Description

Quantity 2

Part Reference KNJ2732

Quantity 1

Part Reference KHP27030

Description

Quantity 2 4 8

Part Reference KHV10990 KHV10460 KHV10450

Description

Quantity 2 1 1 2 1 1 6

Part Reference KHJ1898 KLV12390 KLV12380 BRJ1286 KLV13710 KLV13700 KHJ1360

Nipple with filter G1/4 Tee G1/4 Bracket Mount clamp Phillips pan head screw M6x8 Wire band L = 380 Wire band L = 300 Elbow G1/4 Clamp with band M8 Tee G1/4 Clamp with band M8 Pressure sensor Reducing valve

Electrical part (Refer to 3-17) Item 66 67 68 69

Wire harness Wire band L = 250 Clip Bolt M6x16

Port relief valve (Refer to 3-24) Item 13

Port relief valve

Plate (Refer to 3-25) Item 75

Description Operation label (proportional control)

Clamp (Refer to 3-1) Item 1 2 3

Pipe clamp Pipe clamp Pipe clamp

Line (Refer to 3-1) Item 4 5 6 7 8 9 10

Plug G3/4 Line assembly Line assembly Plug G3/4 Line assembly Line assembly O-ring

(right–hand) (left–hand) (right–hand) (left–hand)

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) • Box wrenches ( 10 mm, 13 mm, 17 mm, 19 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 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 DOUBLE-ACTING CIRCUIT (PROPORTIONAL CONTROL)

Boom line installation

SMIL15CEX8076FB

1

Line Assemblies (8) (9) 1. Set the line assembly (left) (9) on the boom.

SMIL15CEX8077AB

2

3-1 EN

3 - ASSEMBLY

2. Sandwich the line assembly (left) (9) at two locations with two pipe clamps (3) each, and then fasten with two sems bolts (*1) each.

• Fasten one of the pipe clamps (3) at a position 208 mm (8.189 in) from the rear end of the line assembly (left) (9).

SMIL15CEX8078AB

3

SMIL15CEX7677AB

4

SMIL15CEX8080BB

5

3. Set the O-ring (10) on the line assembly (left) (9), and then install the plug (7).

4. Sandwich the line assembly (left) (9) with two pipe clamps (2), and then fasten with two sems bolts (*1).

• Fasten the pipe clamps (2) at a position 205 mm (8.071 in) from the front end of the line assembly (left) (9).

5. Install the line assembly (right) (8) in the same way as the line assembly (left) (9).

3-2 EN

3 - ASSEMBLY

Line Assemblies (5) (6) 1. Set the line assembly (left) (6).

SMIL15CEX8081BB

6

SMIL15CEX7680AB

7

SMIL15CEX7681AB

8

2. Fasten the line assembly (left) (6) with one pipe clamp (1) and two sems bolts (*1).

• Fasten the pipe clamp (1) at a position 127 mm (5.000 in) from the front end of the line assembly (left) (6).

3. Set the O-ring (10) on the rear end of the line assembly (left) (6), then connect the line assembly (left) (9).

3-3 EN

3 - ASSEMBLY

4. Set the O-ring (10) on the front end of the line assembly (left) (6), then install the plug (4).

SMIL15CEX8082AB

9

5. Install the line assembly (right) (5) in the same way as the line assembly (left) (6).

3-4 EN

3 - ASSEMBLY

Upper main line installation

SMIL15CEX8083FB

1

Upper Main Line Installation (left side) 1. Install the bracket (6) on the frame with four sems bolts (1).

Install the manifold (2) on the bracket (6) with two sems bolts (1).

Install the hose adapter (3) on the manifold (2).

Set the O-ring (5) on the hose adapter (3) and connect the hydraulic hose (4).

• Tightening torque: 142.349 lb ft)

157 - 193 N·m (115.797 -

SMIL15CEX8084BB

2

3-5 EN

3 - ASSEMBLY

2. Set the O-ring (5) on the line assembly (left) (*2) and connect the hydraulic hose (4).

• Tightening torque: 142.349 lb ft)

157 - 193 N·m (115.797 -

SMIL15CEX8085AB

3

SMIL15CEX8086AB

4

SMIL15CEX8087BB

5

3. Install the hose adapter (3) on the manifold (2).

Set the O-ring (5) on the hose adapter (3) and connect the hydraulic hose (14).

• Tightening torque: 142.349 lb ft)

157 - 193 N·m (115.797 -

4. Set the O-ring (23) on the control valve (*3) 5B4 port, and connect the hydraulic hose (14) with two split flanges (21) and four hexagon socket head bolts (22).

3-6 EN

3 - ASSEMBLY

Upper Main Line Installation (right side) 1. Install the bracket (9) on the frame with four sems bolts (1).

SMIL15CEX8088AB

6

SMIL15CEX8089AB

7

SMIL15CEX8090AB

8

SMIL15CEX8091AB

9

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

Install the hose adapter (3) on the manifold (2).

Set the O-ring (5) on the hose adapter (3) and connect the hydraulic hose (4).

• Tightening torque: 142.349 lb ft)

157 - 193 N·m (115.797 -

3. Set the O-ring (5) on the line assembly (right) (*4) and connect the hydraulic hose (4).

• Tightening torque: 142.349 lb ft)

157 - 193 N·m (115.797 -

4. Install the elbow (7) on the manifold (2).

Set the O-ring (5) on the elbow (7) and connect the hydraulic hose (8).

A. Left

3-7 EN

3 - ASSEMBLY

5. Set the O-ring (23) on the control valve (*3) 5A4 port, and connect the hydraulic hose (8) with the two split flanges (21) and four hexagon socket head bolts (22).

SMIL15CEX8092BB

10

3-8 EN

3 - ASSEMBLY

6. Install the check valve (18) on the control valve (*3) ck2 port, and then connect the hose adapter (17).

Set the O-ring (16) on the hose adapter (17) and connect the hydraulic hose (15).

Install the elbow (19) on the control valve (*3) ck1 port.

Set the O-ring (16) on the elbow (19) and connect the hydraulic hose (15).

• Tightening torque: 84 - 102 N·m (61.955 - 75.231 lb ft)

SMIL15CEX8093CB

11

3-9 EN

3 - ASSEMBLY

7. Install the bracket (10) on the arm line bracket (*5) with two sems bolts (1).

Sandwich the hydraulic hoses (8) (15) with two hose clamps (11), and then install the plate (12) with two sems bolts (13) in order to fasten the clamps.

• Install the hose clamps (11) with the surfaces with protrusions both facing the (*6) side.

SMIL15CEX8094BB

12

3-10 EN

3 - ASSEMBLY

Pilot line installation - Proportional control

SMIL15CEX7695FB

1

SMIL15CEX7696FB

2

3-11 EN

3 - ASSEMBLY

SMIL15CEX8095FB

3

*2. Control valve *3. Manifold 1. Install the reducing valve (29) on the bracket (19) with two sems bolts (13).

Install the bracket (19) on the rear side of the floor (*1) with two sems bolts (15).

SMIL15CEX7698AB

4

SMIL15CEX7699AB

5

2. Install the solenoid valve (7) on the bracket (11) with two high-strength bolts (8) and two spring washers (9).

Install the bracket (11) on the rear side of the floor (*1) with two sems bolts (15).

3-12 EN

3 - ASSEMBLY

3. Install the hose adapter (6) on the reducing valve (29) T port.

SMIL15CEX7700AB

6

SMIL15CEX7701AB

7

SMIL15CEX7702AB

8

SMIL15CEX7703AB

9

4. Install the tee (18) on the solenoid valve (7) T port.

Connect the reducing valve (29) T port and solenoid valve (7) T port with the nylon hose (5-2).

5. Install the nipple with filter (17) on the reducing valve (29) P port.

6. Install the tee (18) on the solenoid valve (7) P port.

Connect the reducing valve (29) P port and solenoid valve (7) P port with the nylon hose (5-1).

• Install the tee (18) with the horizontal angle of 30° up.

3-13 EN

3 - ASSEMBLY

7. Install the tee (26) and pressure sensor (28) on the reducing valve (29) A1 port.

• Install the tee (26) with the vertical angle of 60° to the left of the adapter.

SMIL15CEX7704AB

10

SMIL15CEX7705BB

11

SMIL15CEX7706AB

12

8. Install the stud (16) and elbow (24) on the control valve (*2) 5a4 port.

Connect the reducing valve (29) A1 port and control valve (*2) 5a4 port with the nylon hose (2-2).

9. Install the tee (26) and pressure sensor (28) on the reducing valve (29) A2 port.

• Install the tee (26) with the vertical angle of 60° to the left of the adapter.

3-14 EN

3 - ASSEMBLY

10. Install the long elbow (4) on the control valve (*2) 5b4 port.

Connect the reducing valve (29) A2 port and control valve (*2) 5b4 port with the nylon hose (2-1), and then fasten with the wire band (3).

• Install the long elbow (4) with the horizontal angle of 65° down.

SMIL15CEX7707AB

13

SMIL15CEX7708AB

14

SMIL15CEX7709AB

15

SMIL15CEX8096AB

16

11. Install the elbow (24) on the manifold (*3) T5 port.

Connect the solenoid valve (7) T port and manifold (*3) T5 port with the nylon hose (5-4).

Install the elbow (24) on the manifold (*3) P5 port.

Connect the solenoid valve (7) P port and manifold (*3) P5 port with the nylon hose (5-3).

12. Install the hose adapter (6) on the solenoid valve (7) A port.

• Install the hose adapter (6) with the vertical angle of 45° to the right of the adapter.

13. Install the elbow (24) on the control valve (*2) a port.

Connect the solenoid valve (7) A port and control valve (*2) a port with the nylon hose (2-3), and then fasten with two wire bands (3).

3-15 EN

3 - ASSEMBLY

14. Fasten the nylon hose at four locations with one mount clamp (20) each, one Phillips pan head screw (21) each, and one wire band (3) each as shown in the diagram.

Fasten the nylon hose with four wire bands (23).

• Fasten the nylon hose together with the pilot control line.

SMIL15CEX7711BB

17

SMIL15CEX8097AB

18

SMIL15CEX8098AB

19

15. Fasten the assembly hose with one wire band (3), four wire bands (22), clamp with band (25) as shown in the diagram.

16. Fasten the assembly hose with two wire bands (3) and clamp with band (27) as shown in the diagram.

3-16 EN

3 - ASSEMBLY

Harness installation - Proportional control

SMIL15CEX7714FB

1

SMIL15CEX7715FB

2

3-17 EN

3 - ASSEMBLY

1. Connect the wire harness (66) and reducing valve (*1).

SMIL15CEX7716AB

3

SMIL15CEX7717BB

4

SMIL15CEX7718AB

5

2. Route the wire harness (66) as shown in the diagram.

Fasten the wire harness (66) at six locations with six wire bands (67).

3. Fasten the three couplers on the wire harness (66) with one clip (68) each and one bolt (69) each.

3-18 EN

3 - ASSEMBLY

4. Connect the solenoid valve (*10) connector to the wire harness (66).

SMIL15CEX7719AB

6

SMIL15CEX7720AB

7

SMIL15CEX7721AB

8

5. Connect the wire harness (66) connector (8-pin) to the frame main harness (*3) and fasten with the wire band (67).

6. Extend the wire harness (66) to the floor side from under the cab.

Connect the wire harness (66) connector (16-pin) to the cab main harness and fasten with the wire band (67).

3-19 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).

3-20 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)

3-21 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.

3-22 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).

3-23 EN

3 - ASSEMBLY

Port relief valve installation 1. Remove the plug, then install the two port relief valves (13) on the control valve (*1).

• Tightening torque: 78.4 - 88.3 N·m (57.825 65.127 lb ft) After installing the port relief valves (13), adjust the relief pressure to match the attachment used. (See the Service Manual.)

SMIL15CEX7722BB

1

3-24 EN

3 - ASSEMBLY

Attachment of plate inside cab

SMIL15CEX7723GB

1

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

2. Attach the foot control operation label (ISO) (75).

3-25 EN

3 - ASSEMBLY

3-26 EN

Index ###_Index_###

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

3-1

C Control lever installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 H Harness installation - Proportional control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 K Kit content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

P Pilot line installation - Proportional control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Port relief valve installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 U Upper main line installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5

EN

SERVICE - Technical Publications & Tools

© 2015 CNH Industrial Italia S.p.A. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

CNH Industrial 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 Industrial Dealer.

CNH Industrial Italia S.p.A. viale delle Nazioni, 55 Modena Italy 41122 EN