CNH Double-acting circuit proportional control kit CX210D Crawler Excavator Instructions Manual

INSTALLATION INSTRUCTIONS

KG2RP264-00

DOUBLE-ACTING CIRCUIT PROPORTIONAL CONTROL KIT

APPROXIMATE INSTALLATION TIME: 25.0 hours

San - 47844469 Issue date March 2015 EN

KG2RP264-00 - DOUBLE-ACTING CIRCUIT PROPORTIONAL CONTROL KIT CASE CONSTRUCTION CX210D

San - 47844469 Issue date March 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 KIT Boom line installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Upper main line installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Pilot line installation - proportional control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Harness installation - Proportional control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Port relief valve installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Control lever installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Installation of nameplate inside cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

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 3-19) Item 75

Description Knob (right-hand) proportional control

Quantity 1

Part Reference KHJ28550

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

Part Reference KRJ37790 KHJ0914 KRJ2682 108R010Y030R KHJ1349 KRJ11470 105R012Y030R KRJ12170 KHJ1349 KHJ1361 KSJ13741 KRJ16050 105R012Y030R KRJ12170 KRJ36930 KHJ0914 KHJ1349 KRJ2682 108R010Y030R KBJ19820 105R010Y025R KRJ11450 KRJ10800 KHJ26310 KHJ1804 KHJ1360 KBJ19810 KHJ1360 KHJ10480

Quantity 1 2 1 2 1 2 1 1 2 2 8 2

Part Reference MFJ71500 105R008Y016R KHJ28770 105R010Y020R KNJ0758 KAJ3807 CNA0584 KBJ22380 KHR26940 KHJ28880 KHH0143 KHJ28580

Double-acting main circuit proportional control (Refer to 3-5) Item 4 5 7 8 9 10 11 12 13 14 15 16 17 18 19 21 22 23 24 25 26 27 28 30 31 32 33 34 35

Description Hydraulic hose O-ring Split flange G1 Hexagon socket head bolt M10x30 Hose adapter Bracket Sems bolt M12x30 Manifold Hose adapter O-ring Hydraulic hose Bracket Sems bolt M12x30 Manifold Hydraulic hose O-ring Hose adapter Split flange G1 Hexagon socket head bolt M10x30 Bracket Sems bolt M10x25 Hose clamp Plate Stud Elbow G3/4 O-ring Hydraulic hose O-ring Check valve

Double-acting pilot circuit proportional control (Refer to 3-9) Item 40 41 42 43 44 45 46 47 48 49 50 53

Description Reducing valve Sems bolt M8x16 Bracket Sems bolt M10x20 Hose adapter G1/4 Tee G1/4 Nipple with filter G1/4 Assembly hose Pressure sensor Elbow Wire band (L = 300) Elbow (G1/4) 1-1

EN

1 - KIT CONTENT

Item 54 55 56

Description

Quantity 4 4 4

Part Reference KHR0319 145N006S008R KHH0142

Description

Quantity 1 3 3

Part Reference KHR39501 KHH0142 KHR1957 KHR1253

Description

Quantity 2

Part Reference BRP0110

Quantity 1

Part Reference KHP27030

Description

Quantity 8 4 4 2

Part Reference KHV10610 KHV10630 105R012Y030R KHV10640

Description Line assembly (left-hand) Line assembly (left-hand) O-ring Plug G3/4 Line assembly (right-hand) Line assembly (right-hand)

Quantity 1 1 2 2 1 1

Part Reference KRV32661 KRV40160 KHJ1361 BRJ1286 KRV32671 KRV40170

Quantity 2 2

Part Reference KHJ1899 KHJ1361

Mount clamp Phillips pan head screw M6x8 Wire band (L = 250)

Electrical part (Refer to 3-15) Item 78 79 80 81

Wire harness Wire band (L = 250) Clip Bolt M6x16

Port relief valve (Refer to 3-18) Item 59

Port relief valve

Plate (Refer to 3-23) Item 72

Description Operation label (proportional control)

Clamp (Refer to 3-1) Item 86 87 88 89

Pipe clamp Pipe clamp Sems bolt M12x30 Pipe clamp

Line (Refer to 3-1) Item 91 92 93 94 95 96

Plug (Refer to 3-1) Item 100 101

Description Plug O-ring

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, 22 mm) • Hexagon wrenches ( 8 mm, 12 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 KIT

Boom line installation

SMIL15CEX2829GB

1

3-1 EN

3 - ASSEMBLY

Line assemblies (91) and (95) 1. Set the line assembly (left) (91) on the boom.

SMIL15CEX2830AB

2

SMIL15CEX2468AB

3

SMIL15CEX2469AB

4

2. Sandwich the line assembly (left) (91) at two locations with two pipe clamps (86) each, and then fasten with two sems bolts (*1) each.

• Fasten one pipe clamp (86) at a position 250 mm (9.8 in) from the rear end of the line assembly (left) (91).

3. Install the plug (94) on the line assembly (left) (91).

3-2 EN

3 - ASSEMBLY

4. Sandwich the line assembly (left) (91) with two pipe clamps (87), and then fasten with two sems bolts (*2).

• Fasten the pipe clamp (87) at a position 285.0 mm (11.2 in) from the front end of the line assembly (left) (91).

5. Install the line assembly (right) (95) in the same way as the line assembly (left) (91).

SMIL15CEX2470BB

5

SMIL15CEX2831BB

6

Line assemblies (92) and (96) 1. Set the line assembly (left) (92).

3-3 EN

3 - ASSEMBLY

2. Fasten the line assembly (left) (92) with the one pipe clamp (89) and the two sems bolts (88).

• Fasten the pipe clamp (89) at a position 110 mm (4.3 in) from the front end of the line assembly (left) (92).

SMIL15CEX2472AB

7

SMIL15CEX2473AB

8

SMIL15CEX2474AB

9

3. Set the O-ring (93) on the rear end of the line assembly (left) (92), and then connect the line assembly (left) (91).

4. Set the O-ring (101) on the front end of the line assembly (left) (92), and then install the plug (100).

5. Install the line assembly (right) (95) in the same way as the line assembly (left) (91).

3-4 EN

3 - ASSEMBLY

Upper main line installation

SMIL15CEX2529FB

1

Upper main line installation (left side) 1. Install the bracket (10) on the frame with four sems bolts (11).

Install the manifold (12) on the bracket (10) with two sems bolts (11).

Install the hose adapter (13) on the manifold (12).

Set the O-ring (14) on the hose adapter (13) and connect the hydraulic hose (15).

• Tightening torque: 184 - 226 N·m (136 - 167 lb ft)

SMIL15CEX2530AB

2

SMIL15CEX2531AB

3

2. Set the O-ring (14) on the line assembly (left) (*1) and connect the hydraulic hose (15).

• Tightening torque: 184 - 226 N·m (136 - 167 lb ft)

3-5 EN

3 - ASSEMBLY

3. Install the hose adapter (9) on the manifold (12).

Set the O-ring (14) on the hose adapter (9) and install the hydraulic hose (19).

• Tightening torque: 184 - 226 N·m (136 - 167 lb ft)

SMIL15CEX2835AB

4

SMIL15CEX2836AB

5

SMIL15CEX2534AB

6

SMIL15CEX2535AB

7

4. Set the O-ring (5) on the control valve (*3) A2 port, and install the hydraulic hose (19) with two split flanges (7) and four hexagon socket head bolts (8).

Upper main line installation (right side) 1. Install the bracket (16) on the frame with four sems bolts (17).

Install the manifold (18) on the bracket (16) with two sems bolts (17).

Install the hose adapter (13) on the manifold (18).

Set the O-ring (14) on the hose adapter (13) and connect the hydraulic hose (15).

• Tightening torque: 184 - 226 N·m (136 - 167 lb ft)

2. Set the O-ring (14) on the line assembly (right) (*2) and connect the hydraulic hose (15).

• Tightening torque: 184 - 226 N·m (136 - 167 lb ft)

3-6 EN

3 - ASSEMBLY

3. Install the hose adapter (22) on the manifold (18).

Set the O-ring (14) on the hose adapter (22) and connect the hydraulic hose (4).

• Tightening torque: 184 - 226 N·m (136 - 167 lb ft)

SMIL15CEX2837AB

8

SMIL15CEX2838BB

9

4. Install the bracket (25) on the housing frame (*4) with two sems bolts (26).

Sandwich the hydraulic hose (4) with two hose clamps (27), and then install the plate (28) with two sems bolts (26) in order to fasten the clamps.

5. Set the O-ring (21) on the control valve (*3) B2 port, and connect the hydraulic hose (4) with two split flanges (23) and four hexagon socket head bolts (24).

SMIL15CEX2839AB

10

3-7 EN

3 - ASSEMBLY

6. Install the check valve (35) on the control valve (*3) P4 port.

Set the O-ring (34) on the check valve (35) and connect the hydraulic hose (33).

Install the stud (30) on the control valve (*3) P3 port, and then install the elbow (31).

Set the O-ring (32) on the elbow (31) and connect the hydraulic hose (33).

• Hydraulic hose tightening torque: 157 - 193 N·m (116 - 142 lb ft)

SMIL15CEX2539BB

11

3-8 EN

3 - ASSEMBLY

Pilot line installation - proportional control

SMIL15CEX2840FB

1

SMIL15CEX2841FB

2

3-9 EN

3 - ASSEMBLY

SMIL15CEX2542FB

a. Hose assembly b. Code *1. Floor

*2. *3.

3

Manifold Control valve

1. Install the reducing valve (40) on the bracket (42) with two sems bolts (41).

Install the bracket (42) on the floor (*1) with two sems bolts (43).

SMIL15CEX2543AB

4

SMIL15CEX2544AB

5

2. Install the hose adapter (44) on the reducing valve (40) T port.

• Tightening torque: 25.4 - 31.4 N·m (18.73 - 23.16 lb ft)

3-10 EN

3 - ASSEMBLY

3. Install the elbow (53) on the manifold (*2) T5 port.

Connect the reducing valve (40) T port and manifold (*2) T5port with the assembly hose (47) (T5).

SMIL15CEX2842AB

6

SMIL15CEX2546AB

7

SMIL15CEX2547AB

8

4. Install the nipple with filter (46) on the reducing valve (40) P port.

• Tightening torque: 25.4 - 31.4 N·m (18.73 - 23.16 lb ft)

5. Install the elbow (53) on the manifold (*2) P5 port.

Connect the reducing valve (40) P port and manifold (*2) P5 port with the assembly hose (47) (P5).

3-11 EN

3 - ASSEMBLY

6. Install the tee (45) on the reducing valve (40) A1 port.

• Tightening torque: 25.4 - 31.4 N·m (18.73 - 23.16 lb ft)

SMIL15CEX2548BB

9

7. Install the elbow (49) on the control valve (*3) pb2 port.

Connect the reducing valve (40) A1 port and control valve (*3) pb2 port with the assembly hose (47) (Y2).

SMIL15CEX2549AB

10

3-12 EN

3 - ASSEMBLY

8. Install the tee (45) on the reducing valve (40) A2 port.

• Tightening torque: 25.4 - 31.4 N·m (18.73 - 23.16 lb ft)

SMIL15CEX2550BB

11

SMIL15CEX2551AB_

12

9. Install the elbow (49) on the control valve (*3) pa2 port.

Connect the reducing valve (40) A2 port and control valve (*3) pa2 port with the assembly hose (47) (Y1).

3-13 EN

3 - ASSEMBLY

10. Fasten the assembly hose that come out from the reducing valve (40) with four mount clamps (54), four Phillips pan head screws (55), and four wire bands (56).

Fasten the assembly hose that comes out from the reducing valve (40) with four wire bands (50).

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

Install the two pressure sensors (48) on the reducing valve (40).

SMIL15CEX2843BB

13

SMIL15CEX2844AB

14

11. Fasten the assembly hose with four wire bands (50).

3-14 EN

3 - ASSEMBLY

Harness installation - Proportional control

SMIL14II01269FB

1

SMIL14II01270FB

2

3-15 EN

3 - ASSEMBLY

1. Connect the wire harness (78) and the reducing valve (*1).

SMIL14II01271AB

3

SMIL14II01272BB

4

SMIL14II01273AB

5

2. Route the wire harness (78) as shown in the diagram.

Fasten the wire harness (78) at 6 locations with 6 wire bands (*2).

3. Fasten the 3 couplers on the wire harness (78) with 1 clip (80) each and 1 bolt (81) each.

3-16 EN

3 - ASSEMBLY

4. Connect the wire harness (78) connector (8-pin) to the frame main harness (*3) and fasten with the wire band (79).

SMIL14II01274AB

6

SMIL14II01275AB

7

5. Extend the wire harness (78) to the floor side from under the cab.

Connect the wire harness (78) connector (16-pin) to the cab main harness and fasten with the wire band (79).

3-17 EN

3 - ASSEMBLY

Port relief valve installation 1. Remove the plug, and then install the two port relief valves (59) on the control valve (*1).

• Tightening torque: 78.4 - 88.3 N·m (57.8 - 65.1 lb ft).

SMIL15CEX2553BB

1

After installing the port relief valve (59), adjust the relief pressure to match the attachment used.

(See the Service Manual.)

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

Installation of nameplate inside cab

SMIL14II01276GB

1

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

2. Attach the operation label (proportional control) (72).

3-23 EN

3 - ASSEMBLY

3-24 EN

Index ###_Index_###

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

3-1

C Control lever installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 H Harness installation - Proportional control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 I Installation of nameplate inside cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 K Kit content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

P Pilot line installation - proportional control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Port relief valve installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 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 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