CNH Hose burst check valve (HBCV) long reach (LR)CX210D Long reach excavator Instructions Manual

INSTALLATION INSTRUCTIONS

KG2RP389-00

HOSE BURST CHECK VALVE (HBCV) LONG REACH (LR) KIT

APPROXIMATE INSTALLATION TIME: 8.0 hours

San - 47928776 Issue date September 2015 EN

KG2RP389-00 - HOSE BURST CHECK VALVE (HBCV) LONG REACH (LR) KIT CASE CONSTRUCTION CX210D Long Reach

San - 47928776 Issue date September 2015 EN

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

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

3 ASSEMBLY HOSE BURST CHECK VALVE Hose Burst Check Valve installation on boom cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Boom cylinder line installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Installation on arm cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Arm cylinder line installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Pilot line installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Harness installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

EN

EN

1 - KIT CONTENT

1 - KIT CONTENT Kit content NOTE: please refer to the Parts Manual for parts orders.

Pilot Hose Burst Check Valve (HBCV) (Refer to 3-13) Item 3 4 5 5-1 5-2 6 6-1 6-2 7 8 9 10

Description Tee G1/4 x G3/8 Tee G3/8 Assembly hose 5-1 - 5-2 Rubber hose D14 Rubber hose D13 Assembly hose 6-1 - 6-2 Rubber hose V6 Rubber hose A6 Wire band L = 250 Wire band L = 380 Tee G1/4 x G3/8 Elbow

Quantity 2 2 – 1 1 – 1 1 8 18 1 1

Part Reference KHJ11560 KHJ31880 KRJ36830 KHJ33850 KHJ30750 KRJ36840 KHJ22110 KHJ18350 KHH0142 KAR0017 KHJ13900 KHJ28590

Quantity 1 1 1 1 4 1 1

Part Reference KHR41950 KHJ18180 KHR15490 KHR11650 KHH0142 KHR1317 KHJ1213

Quantity 4 2 8 4 10 4 1 3

Part Reference 102R012Y050R 102R016Y070R 102R016Y085R KHN0296 KHN0297 KAV1627 KRV24750 KRV24760

Quantity 1 1 2 1 2 1 1 1 –

Part Reference KHJ0872 KHJ0884 KHJ0894 KHV0373 KNJ0758 KNJ0759 KNJ1106 KRV19790 KRV19770

Electrical part (Refer to 3-17) Item 13 14 15 16 17 18 19

Description Pressure sensor Stud G1/4 x M8 Overload warning rocker switch Overload warning wire harness Wire band L = 250 Clip Special bolt M8x16

Clamp (Refer to 3-10) Item 1 2 3 4 5 6 7 16

High-strength High-strength High-strength High-strength High-strength Pipe clamp Plate Plate

Description bolt M12 x 50 bolt M16 x 70 bolt M16 x 85 washer M12 washer

Boom Hose Burst Check Valve (HBCV) line (Refer to 3-5) Item 1 2 3 4 5 6 7 84 85

Description Tee G1/4 x G3/8 x G3/8 Tee G3/8 Stud G1/4 Stud G3/8 Hose adapter G1/4 Hose adapter G3/8 Hose adapter G1/4 x G3/8 Hydraulic hose Assembly hose 85-1 to 85-2 1-1

EN

1 - KIT CONTENT

Item 85-1 85-2 91

Description Hydraulic hose PI Hydraulic hose DR Wire band L = 380

Quantity 1 1 6

Part Reference KHJ1435 KHJ1435 KAR0017

Quantity 1 1 1 1 1 16 2 2 2

Part Reference KHJ0894 KNJ0759 KNJ1106 KRV25330 KHJ17480 KHJ17480 KAR0016 KRV24290 KRV44920 KHJ16820

Quantity 1 4 2 1 4

Part Reference KRV12070 108R010Y035R KHJ0913 KRV11110 108R010Y070R

Quantity 1 4 2 1 4

Part Reference KRV12080 108R010Y035R KHJ0913 KRV11110 108R010Y070R

Quantity 1 4 2 4 1

Part Reference KSV17260 108R012Y070R KHJ0914 108R012Y035R KRV43220

Arm Hose Burst Check Valve (HBCV) line (Refer to 3-10) Item 8 9 10 11 11-1 11-2 12 13 14 15

Description Stud G1/4 Hose adapter G3/8 Hose adapter G1/4 x G3/8 Assembly hose 11-1 - 11-2 Hydraulic hose PI Hydraulic hose DR Wire band L = 150 Line assembly Line assembly (HBCV) Hydraulic hose L = 2100

Left-hand boom cylinder (Refer to 3-1) Item 2 3 4 5 6

Description Line assembly (left-hand – HBCV) Hexagon socket head bolt M10×35 O-ring Holding valve Hexagon socket head bolt M10×70

Right-hand boom cylinder (Refer to 3-1) Item 2 3 4 5 6

Description Line assembly (right-hand – HBCV) Hexagon socket head bolt M10×35 O-ring Holding valve Hexagon socket head bolt M10×70

Arm cylinder (Refer to 3-8) Item 1 2 3 6 7

Description Holding valve Hexagon socket head bolt M12x70 O-ring Hexagon socket head bolt M12x35 Line assembly (HBCV)

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 ( 8 mm, 10 mm, 12 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 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 HOSE BURST CHECK VALVE

Hose Burst Check Valve installation on boom cylinder Installation on left-hand boom cylinder

SMIL15CEX8235FB

1

3-1 EN

3 - ASSEMBLY

1. Remove the bolt (M14×2) (*3), and then remove the clamp (*2).

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

• Tightening torque: 44.844 lb ft)

41.6 - 60.8 N·m (30.683 -

SMIL15CEX8236BB

2

SMIL15CEX8237BB

3

2. Set the O-ring (4) on the end of the line assembly (left HBCV) (2), and then install on the holding valve (5) with four hexagon socket head bolts (3).

• Tightening torque: 44.844 lb ft)

41.6 - 60.8 N·m (30.683 -

Set the line assembly (left HBCV) (2) and line (*4) on the clamp (*2), and then fasten with the bolt (M14×2) (*3).

• Tightening torque: 54.801 lb ft)

50.9 - 74.3 N·m (37.542 -

3-2 EN

3 - ASSEMBLY

Installation on right-hand boom cylinder

SMIL15CEX8238FB

4

1. Remove the bolt (M14×2) (*7), and then remove the clamp (*6).

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

• Tightening torque: 44.844 lb ft)

41.6 - 60.8 N·m (30.683 -

SMIL15CEX8239BB

5

3-3 EN

3 - ASSEMBLY

2. Set the O-ring (4) on the end of the line assembly (right HBCV) (2), and then install on the holding valve (5) with four hexagon socket head bolts (3).

• Tightening torque: 44.844 lb ft)

41.6 - 60.8 N·m (30.683 -

Set the line assembly (right HBCV) (2) and line (*8) on the clamp (*6), and then fasten with the bolt (M14×2) (*7).

• Tightening torque: 54.801 lb ft)

50.9 - 74.3 N·m (37.542 -

SMIL15CEX8240BB

6

3-4 EN

3 - ASSEMBLY

Boom cylinder line installation

SMIL15CEX8335G

1

3-5 EN

3 - ASSEMBLY

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

Install the stud (3) on the right side holding valve (*2) PL port, and then connect the hose adapter (7).

Connect the left side holding valve (*1) PL port and right side holding valve (*2) PL port with the hydraulic hose (85-1).

SMIL15CEX8336BB

2

SMIL15CEX8337BB

3

2. Install the hose adapter (6) on the left side holding valve (*1) DR port.

Install the stud (4) 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 hydraulic hose (85-2).

3-6 EN

3 - ASSEMBLY

3. Install the hose adapter (5) on the left side holding valve (*1) C port.

Install the hose adapter (5) 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 (84).

SMIL15CEXY445AB

4

SMIL15CEX8339BB

5

4. Fasten the hydraulic hoses (85-1) and (85-2) with two wire bands (91).

• Fasten the hydraulic hoses (85-1) and (85-2) together with the line (*3).

Fasten the hydraulic hose (84) with two wire bands (91).

• Fasten the hydraulic hose (84) together with the line (*3).

3-7 EN

3 - ASSEMBLY

Installation on arm cylinder

SMIL15CEX8340FB

1

1. Remove the bolt (M12x1.75) (*2), and then remove the clamp (*3).

SMIL15CEX8341BB

2

3-8 EN

3 - ASSEMBLY

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

• Tightening torque: 81.058 lb ft)

74.9 - 109.9 N·m (55.243 -

Set the O-ring (3) on the end of the line assembly (HBCV) (7), and then install the line assembly (HBCV) (7) on the holding valve (1) with four hexagon socket head bolts (6).

• Tightening torque: 81.058 lb ft)

74.9 - 109.9 N·m (55.243 SMIL15CEX8342AB

3

SMIL15CEX8343AB

4

3. Set the line assembly (HBCV) (7) on the clamp (*3), and then fasten with the bolt (M12x1.75) (*2).

• Tightening torque: 49.859 lb ft)

46.2 - 67.6 N·m (34.075 -

3-9 EN

3 - ASSEMBLY

Arm cylinder line installation

SMIL15CEXY446FB

1

1. Set the two line assemblies (13) on the boom.

SMIL15CEXY447AB

2

SMIL15CEXY448AB

3

2. Install the plate (7) with two high-strength bolts (3) and two high-strength washers (5).

Fasten the two line assemblies (13) with the pipe clamp (6), high-strength bolt (1), and high-strength washer (4).

• Fasten the pipe clamp (6) at a position 75 mm (2.953 in) from the rear end of the line assembly (13).

3-10 EN

3 - ASSEMBLY

3. Install the plate (16) with two high-strength bolts (3) and two high-strength washers (5).

Fasten the two line assemblies (13) with the pipe clamp (6), high-strength bolt (1), and high-strength washer (4).

Connect the two hydraulic hoses (15) to the two line assemblies (13).

• Fasten the pipe clamp (6) at a position 75 mm (2.953 in) from the front end of the line assembly (13).

SMIL15CEXY449AB

4

SMIL15CEXY450AB

5

SMIL15CEXY451AB

6

SMIL15CEXY452AB

7

4. Set the two line assemblies (HBCV) (14) on the boom.

Connect the two hydraulic hoses (15) to the two line assemblies (HBCV) (14).

5. Install the plate (16) with two high-strength bolts (3) and two high-strength washers (5).

Fasten the two line assemblies (HBCV) (14) with the pipe clamp (6), high-strength bolt (1), and high-strength washer (4).

• Fasten the pipe clamp (6) at a position 190 mm (7.480 in) from the rear end of the line assembly (HBCV) (14).

6. Install the plate (16) with two high-strength bolts (3) and two high-strength washers (5).

Fasten the two line assemblies (HBCV) (14) with the pipe clamp (6), high-strength bolt (1), and high-strength washer (4).

Connect the hydraulic hose (11-1) and hydraulic hose (11-2) to the two line assemblies (HBCV) (14).

• Fasten the pipe clamp (6) at a position 220 mm (8.661 in) from the front end of the line assembly (HBCV) (14).

3-11 EN

3 - ASSEMBLY

7. Install the stud (8) and hose adapter (10) on the holding valve (*1) PL port.

Connect the hydraulic hose (11-1) to the holding valve (*1) PL port.

Install the hose adapter (9) on the holding valve (*1) DR port.

Connect the hydraulic hose (11-2) to the holding valve (*1) DR port.

SMIL15CEXY453AB

8

SMIL15CEXY454AB

9

8. Fasten the two hydraulic hoses (15) with seven wire bands (12).

9. Fasten the hydraulic hoses (11-1) (11-2) with nine wire bands (12).

• If there is excess hose, adjust at *n positions.

SMIL15CEXY455AB

10

SMIL15CEXY456AB

11

10. Install the clamps (*10) with two high-strength bolts (2) and two high-strength washers (5).

3-12 EN

3 - ASSEMBLY

Pilot line installation

SMIL15CEX8350FB

1

SMIL15CEX8351FB

2

3-13 EN

3 - ASSEMBLY

a. Assembly hose b. Code *1. Hydraulic tank *3. Holding valve

*4. Holding valve *5. Control valve *10. HBCV line (PL), *11. HBCV line (DR)

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

1. Install the tee (3) on the hydraulic tank (*1).

SMIL15CEX8352AB

3

SMIL15CEX8353AB

4

SMIL15CEX8354AB

5

2. Connect the hydraulic tank (*1) and holding valve (*4) DR port with the rubber hose (5-1).

Fasten the rubber hose (5-1) with four wire bands (8).

• Fasten the rubber hose (5-1) together with the boom line (*2).

3. Remove the elbow and pilot line V1 (*6) from the control valve (*5) pb8 port, and then install the tee (4).

Install the elbow (10) on the tee (4), and then connect the pilot line V1 (*6).

3-14 EN

3 - ASSEMBLY

4. Fasten the rubber hose (6-1) with two wire bands (7).

SMIL15CEX8355AB

6

SMIL15CEX8356AB

7

SMIL15CEX8357AB

8

SMIL15CEX8358AB

9

5. Connect the control valve (*5) pb8 port and holding valve (*3) PL port with the rubber hose (6-1).

Fasten the rubber hose (6-1) with four wire bands (8).

• Fasten the rubber hose (6-1) together with the boom line (*2).

• Connect the rubber hose (6-1) so that it does not interfere with the bucket line.

6. Remove the tee and pilot line A2 (*8) from the control valve (*5) pb5 port, and then install the tee (4).

Install the tee (9) on the tee (4), and then connect the pilot line A2 (*8).

7. Connect the control valve (*5) pb5 port and HBCV line (PL) (*10) with the rubber hose (6-2).

3-15 EN

3 - ASSEMBLY

8. Install the tee (3) on the hydraulic tank (*1).

Connect the hydraulic tank (*1) and HBCV line (DR) (*11) with the rubber hose (5-2).

Fasten the rubber hoses (6-2) (5-2) with six wire bands (7).

• Fasten the rubber hoses (6-2) and (5-2) together with the arm line (*13).

SMIL15CEX8359CB

10

SMIL15CEX8360AB

11

9. Fasten the rubber hoses (6-1) and (5-1) with seven wire bands (8).

• Fasten the rubber hoses (6-1) and (5-1) together with the boom line (*14).

3-16 EN

3 - ASSEMBLY

Harness installation

SMIL15CEX8361FB

1

1. Install the pressure sensor (13) on the stud (14).

• Tightening torque: 82 - 98 N·m (60.480 - 72.281 lb ft) Install the stud (14) and pressure sensor (13) on the holding valve (*1) C port.

Install the overload warning wire harness (16) on the pressure sensor (13), and then fasten with the wire band (17).

SMIL15CEX8362AB

2

SMIL15CEX8363AB

3

2. Route the overload warning wire harness (16).

Fasten the overload warning wire harness (16) with two wire bands (17).

• Fasten the overload warning wire harness (16) together with the hydraulic hose (*3).

Fasten the overload warning wire harness (16) with four wire bands (*4).

• Fasten the overload warning wire harness (16) together with the boom line.

3-17 EN

3 - ASSEMBLY

3. Connect it to the frame main harness (*2) connector (3-pin).

Fasten the overload warning wire harness (16) with the clip (18), special bolt (19), and wire band (17).

Fasten the overload warning wire harness (16) with one wire band (*4).

• Fasten the overload warning wire harness (16) together with the hydraulic hose (*3).

SMIL15CEX8364AB

4

SMIL15CEX8365AB

5

4. Connect the overload warning rocker switch (15) to the right console harness (*5) CN.B11 (10-pin).

3-18 EN

Index ###_Index_###

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

3-5

H Harness installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Hose Burst Check Valve installation on boom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 I Installation on arm cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8

K Kit content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

P Pilot line installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

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