CNH Low flow hydraulic kit CX210C Crawler excavator Installation Instructions Manual 84573091 - PDF

INSTALLATION INSTRUCTIONS

KG1RP607-00

LOW FLOW HYDRAULIC KIT

APPROXIMATE INSTALLATION TIME: 20 hours

Le - 84573091 2106-00W-161 Issue date January 2012 EN

KG1RP607-00 - LOW FLOW HYDRAULIC KIT CASE CONSTRUCTION CX210C

Le - 84573091 2106-00W-161 Issue date January 2012 EN

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

2 GENERAL INFORMATION Advice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

3 ASSEMBLY ROTARY Hydraulic line - Depressurising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Hydraulic pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Hydraulic line - Install (On boom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Hydraulic line - Install (On upperstructure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Hydraulic line - Install (Pilot line) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Sensing system - Install (Harness) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 Safety sign - Install (Inside cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

EN

1 - KIT CONTENT

1 - KIT CONTENT General specification CX210C NA

Hydraulic pump (refer to 3-9) Code 2 3 4 5 6

Part Number 862-10030 150409A1 KRJ10300 154697A1 KRJ12620

Description Hexagon socket head bolt (108R010Y030R) High-strength washer (KEH0114) 2nd option gear pump O-ring (LBQ0853) Power take-off for gear pump

2 2 1 1 1

Description Add-on 2nd option control valve

1

Qty

Remarks M10x30 M10

Qty

Remarks

Qty

Remarks

Control valve (refer to 3-10) Code 1

Part Number KRJ10330

2nd Double-acting Main Circuit (refer to 3-19) Part Number Code 1 KBJ12450 2 150496A1 5 151650A1 6 157581A1 7 KHJ11760 8 168988A1 9 157585A1 10 157936A1 11 KHJ15660 12 KRJ29680 13 166052A1 14 KRJ11580 15 KRJ11590 16 ABV0829 17 KRJ29960 18 KRJ29970

Description Hydraulic hose Wire band (KHH0142) Hose adapter (KNJ0604) Elbow (KHJ0345) Hydraulic hose Hose adapter (KHJ1778) Elbow (KHJ0350) Elbow (KHJ0642) Hydraulic hose Bracket Sems bolt (105R010Y025R) Hose clamp Bracket Tee Hydraulic hose Hydraulic hose

1 3 2 1 1 1 1 1 1 1 4 2 1 1 1 1

L=250 G1/2 G1 70K-25x1000 G3/4xG1/2 G1/2 G3/4xG1/2

M10x25

G1–G3/4-G1

2nd Double-acting Pilot Circuit (refer to 3-26 and 3-36) Part Number Code 2 150913A1 3 KBJ15510 4 150933A1 5 150496A1 9 KHJ15190 10 627-10035 11 150409A1 12 159002A1 13 KHJ14000 14 162554A1 15 161841A1 16 166351A1 17 152127A1

Description Elbow (KHJ0341) Assembly hose Elbow (KHJ0348) Wire band (KHH0142) Bracket High-strength bolt (102R010Y035R) High-strength washer (KEH0114) Plug (KHJ0363) Solenoid valve Stud (KHJ0626) Nipple (with filter) (CNA0584) Sems bolt (105R010Y020R) Hose adapter (KNJ0758)

Remarks

Qty 1 1 1 7 1 2 2 1 1 1 1 2 2

G1/4 G1/4 L=250 M10x35 M10 G1/4 G1/4 G1/4 M10x20 G1/4

1-4 EN

1 - KIT CONTENT

Plug (refer to 3-26 and 3-36) Code 1 5 7 8 17 18 19

Part Number KHR28610 150496A1 150860A1 840-168 152127A1 158962A1 166345A1

Description Multi-purpose + 2nd option S/V wire harness Wire band (KHH0142) Mount clamp (KHR0319) Phillips pan head screw (145T006S008R) Hose adapter (KNJ0758) Clip (KHR1317) Sems bolt (105R008Y016R)

Remarks

Qty 1 8 7 7 2 2 2

L=250 M6x8 G1/4 M8x16

Nameplate (refer to 3-39) Code 7

Part Number KHP11720

Description Operation label (Switch control)

Qty

Remarks

Qty

Remarks

1

Attachment : Clamp (refer to 3-11) Code 1 2 3 4 5 6 7 11 13

Part Number KHV10480 166352A1 KNV13810 167183A1 KNV13820 KHV10500 KHV11640 KRV19680 KRV19670

Description Pipe clamp Sems bolt (105R012Y030R) Seating (boom top left ) Sems bolt (105R012Y060R) Seating (boom top right) Pipe clamp Pipe clamp Seating (boom center HBCV + 2nd option) Seating (boom foot HBCV + 2nd option)

6 20 3 18 3 6 2 2 1

M12x30 M12x60

Attachment : Line (refer to 3-11) Code 8 9 14 15 16 17

Part Number KRV19190 KRV19180 KRV32700 KRV32720 KRV32710 158841A1

Description Line assembly (right) Line assembly (left) Line assembly (left) Line assembly (drain) Line assembly (right) Plug (KHJ0480)

Remarks

Qty 1 2 1 1 1 3

G1/2

1-5 EN

2 - GENERAL INFORMATION

2 - GENERAL INFORMATION Advice CX210C 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 (0.5 17 mm (0.7 19 mm (0.7 27 mm (1.1 36 mm (1.4 41 mm (1.6

in); in); in); in) in); in)

•

Box wrenches : 13 mm (0.5 in); 17 mm (0.7 in); 19 mm (0.7 in); 27 mm (1.1 in) 36 mm (1.4 in); 41 mm (1.6 in)

•

Hexagon wrenches : 8 mm (0.3 in)

•

Phillips screwdriver : (No. 3)

•

Rag

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.

2-6 EN

3 - ASSEMBLY

3 - ASSEMBLY ROTARY

Hydraulic line - Depressurising CX210C NA

1.

2.

3.

Place 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.

LPIL009I001A01

1

LPIL009I002A

2

LPIL009I003B

3

Switch the ignition key (a) OFF, check that the engine has stopped, then switch the ignition key ON again.

Do not start the engine.

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.

3-7 EN

3 - ASSEMBLY

4.

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.

LPIL009I004A

4

3-8 EN

3 - ASSEMBLY

Hydraulic pump - Install CX210C NA

1.

2.

Install the power take-off (6) for the gear pump on the hydraulic pump (*1) with the 4 bolts (*3).

Tightening torque: 30.0 - 36.6 N·m (265.5 - 323.9 lb in) The bolts (*3) are accessories for the power take-off (6) for the gear pump.

6SDPRD-007

1

6SDPRD-008

2

Set the O-ring (5) on the 2nd option gear pump (4), and then install with the 2 hexagon socket head bolts (2) and 2 high-strength washers (3).

Tightening torque: 30.0 - 36.6 N·m (265.5 - 323.9 lb in) After installing the 2nd option gear pump (4), bleed off air using the air bleed port (*2).

(See the Service Manual).

3-9 EN

3 - ASSEMBLY

Control valve - Install CX210C NA

1.

Install the add-on 2nd option control valve (1) on the control valve (*1) with the 4 nuts (1a) and 4 tie rods (1b) Tightening torque: 116 - 128 N·m (1026.7 - 1132.9 lb in) Replace the O-ring (1c) and tie rods (1b) with new ones.

The nuts (1a), tie rods (1b), and O-ring (1c) are accessories for the add-on 2nd option control valve.

YMGQDI-004

1

3 - 10 EN

3 - ASSEMBLY

Hydraulic line - Install (On boom) CX210C NA

58112105

1

Line assembly (drain) (15) and line assembly (left) (14) 1.

Set the line assembly (drain) (15) and line assembly (left) (14).

632D6AA3

2

3 - 11 EN

3 - ASSEMBLY

2.

3.

Fasten the seating (boom foot HBCV+2nd option) (13) (KG1RP607-00/ KG1RP620-00/ KG1RP621-00) or seating (boom foot 2nd option) (12) (KG1RP606-00/ KG1RP608-00) with 2 sems bolts (4).

Fasten the line assembly (drain) (15) and line assembly (left) (14) with the 1 pipe clamp (1) and the 2 sems bolts (2).

Fasten the pipe clamp (1) at a position 170 mm (6.7 in) from the rear end of the line assembly (drain) (15).

AF757287

3

B6F77567

4

Fasten the seating (boom top left) (3) and pipe clamp (1) with the 2 sems bolts (4).

Fasten the line assembly (drain) (15) and line assembly (left) (14) with the 1 pipe clamp (1) and the 2 sems bolts (2).

Fasten the pipe clamp (1) at a position 65 mm (2.55 in) from the front end of the line assembly (drain) (15) and at a position 84 mm (3.3 in) from the front end of the line assembly (left) (14).

3 - 12 EN

3 - ASSEMBLY

4.

Fasten the seating (boom center HBCV+2nd option) (11) (KG1RP607-00/ KG1RP620-00/ KG1RP621-00) or seating (boom center 2nd option) (10) (KG1RP606-00/ KG1RP608-00) in 2 locations with the 2 sems bolts (4) each.

Fasten the line assembly (drain) (15) and line assembly (left) (14) at 2 locations with 1 pipe clamp (1) each and 2 sems bolts (2) each.

DD6DF797

5

772842B9

6

9A386463

7

Line assembly (right) (16) 5.

6.

Set the line assembly (right) (16).

Fasten the line assembly (right) (16) with the 1 pipe clamp (6) and the 2 sems bolts (2).

Fasten the pipe clamp (6) at a position 170 mm (6.7 in) from the rear end of the line assembly (right) (16).

3 - 13 EN

3 - ASSEMBLY

7.

8.

Fasten the seating (boom top right) (5) and pipe clamp (6) with the 2 sems bolts (4).

Fasten the line assembly (right) (16) with the 1 pipe clamp (6) and the 2 sems bolts (2).

Fasten the pipe clamp (6) at a position 84 mm (3.3 in) from the front end of the line assembly (right) (16).

A00F1471

8

D1A34208

9

Fasten the line assembly (right) (16) at 2 locations with the 1 pipe clamp (6) each and the 2 sems bolts (2) each.

3 - 14 EN

3 - ASSEMBLY

Line assemblies (left) (9) 9.

10.

Set the 2 line assemblies (left) (9) and connect with the line assembly (drain) (15) and line assembly (left) (14).

95FBF09E

10

AE91C05F

11

Remove the 2 sems bolts (*2) that are used to install the pipe clamp (*1).

Fasten the seating (boom top left) (3) with the 2 sems bolts (4).

Fasten the 2 line assemblies (left) (9) with the 1 pipe clamp (1) and the 2 sems bolts (*2).

Fasten the pipe clamp (1) at a position 100 mm (3.93 in) from the end of the line assembly (left) (9).

3 - 15 EN

3 - ASSEMBLY

11.

Fasten the pipe clamp (7) and seating (boom top left) (3) with the 2 sems bolts (4).

Fasten the 2 line assemblies (left) (9) with the 1 pipe clamp (1) and the 2 sems bolts (2).

Fasten the pipe clamp (1) at a position 490 mm (19.3 in) from the front end of the B seating (boom top left) (3).

F603952B

12

7D978CBF

13

Line assembly (right) (8) 12.

Set the line assembly (right) (8) and connect to the line assembly (right) (16).

3 - 16 EN

3 - ASSEMBLY

13.

14.

Remove the 2 sems bolts (*2) that are used to install the pipe clamp (*1).

Fasten the seating (boom top right) (5) with the 2 sems bolts (4).

Fasten the line assembly (right) (8) with the 1 pipe clamp (6) and the 2 sems bolts (*2).

Fasten the pipe clamp (6) at a position 100 mm (3.93 in) from the end of the line assembly (right) (8).

CE70B77C

14

E9EDCA43

15

Fasten the pipe clamp (7) and seating (boom top right) (5) with the 2 sems bolts (4).

Fasten the line assembly (right) (8) with the 1 pipe clamp (6) and the 2 sems bolts (2).

Fasten the pipe clamp (6) at a position 490 mm (19.3 in) from the end of the B seating (boom top right) (5).

3 - 17 EN

3 - ASSEMBLY

Plug (17) installation 15.

Install the 3 plugs (17) at the end of line.

41497415

16

3 - 18 EN

3 - ASSEMBLY

Hydraulic line - Install (On upperstructure) CX210C NA

20118D5C

1

Main line installation

3 - 19 EN

3 - ASSEMBLY

1.

2.

Install the hose adapter (5) at the hydraulic oil tank (*1) D6 port.

Connect the hydraulic oil tank (*1) D6 port and the line assembly (drain) (*2) with the hydraulic hose (1).

JKZMR4-003

2

530E700D

3

Install the elbow (10) at the control valve (*5) AR2 port.

3 - 20 EN

3 - ASSEMBLY

3.

4.

Connect the control valve (*5) AR2 port and the line assembly (left) (*3) with the hydraulic hose (17).

5A6397BC

4

6C3EC81F

5

Install the hose adapter (8) on the control valve (*5) BR2 port.

3 - 21 EN

3 - ASSEMBLY

5.

6.

Connect the control valve (*5) BR2 port and the line assembly (right) (*4) with the hydraulic hose (18).

A115CF44

6

C337935E

7

Install the bracket (12) on the housing frame (*8) with the 2 sems bolts (13).

Sandwich the hydraulic hoses (1), (17) and (18) with the 2 hose clamps (14), and then fasten the bracket (15) with 2 sems bolts (13).

Install the hose clamps (14) with the surfaces with protrusions both facing the cab side.

3 - 22 EN

3 - ASSEMBLY

7.

8.

Fasten the hydraulic hoses (1) and (17) with 2 wire bands (2).

The wire band location dimensions on hydraulic hoses (1) and (17) are as follows: - dimension L2 = 195 mm (7.7 in).

- dimension L3 = 260 mm (10.2 in).

The wire band location dimensions on hydraulic hoses (1), (17) and (18): - dimension L1 = 830 mm (32.7 in).

Fasten the hydraulic hoses (17) and (18) with the wire band (2).

C5143041

8

JKZMR4-010

9

Install the elbow (9) at the control valve (*5) Pr port.

3 - 23 EN

3 - ASSEMBLY

9.

10.

Install the hose adapter (5) on the hydraulic pump (*6) A4 port.

Connect the control valve (*5) Pr port and the hydraulic pump (*6) A4 port with the hydraulic hose (11).

JKZMR4-011

10

JKZMR4-012

11

Fasten the hydraulic hose (11) with the clamp (*7) On hydraulic hose (11): - dimension L1 = 650 mm (25.6 in)

3 - 24 EN

3 - ASSEMBLY

11.

Install the elbow (6) on the hydraulic pump (*6) B4 port.

Remove the hydraulic hose (*8) from the suction line (*7).

Install the tee (16) on the suction line (*7),and then connect the hydraulic hose (*8).

Connect the hydraulic pump (*6) B4 port and the suction line (*7) with the hydraulic hose (7).

E377842B

12

3 - 25 EN

3 - ASSEMBLY

Hydraulic line - Install (Pilot line) CX210C NA

CZPI3R-263

1

Pilot line installation

3 - 26 EN

3 - ASSEMBLY

CZPI3R-264

2

Pilot line installation under the floor

3 - 27 EN

3 - ASSEMBLY

CZPI3R-265

3

Hose connection diagram (3) Assembly hose (3)a Hose part number (3)b Hose part name

(13) Solenoid valve (*2) Manifold (*3) control valve 1.

Install the solenoid valve (13) on the bracket (9) with the 2 sems bolts (16).

Install the bracket (9) on the floor (*1) with 2 highstrength bolts (10) and 2 high-strength washers (11).

CZPI3R-266

4

3 - 28 EN

3 - ASSEMBLY

2.

Install the stud (14) on the solenoid valve (13) T port.

CZPI3R-267

5

3 - 29 EN

3 - ASSEMBLY

3.

Install the hose adapter (17) (KG1RP607-00) or the tee (6) (KG1RP608-00) on the manifold (*2) T5 port.

Connect the solenoid valve (13) T port and manifold (*2) T5 port with the assembly hose (3/T6).

CZPI3R-268

6

3 - 30 EN

3 - ASSEMBLY

4.

Install the nipple (15) on the solenoid valve (13) G port.

CZPI3R-269

7

3 - 31 EN

3 - ASSEMBLY

5.

Install the hose adapter (17) (KG1RP607-00) or the tee (6) (KG1RP608-00) on the manifold (*2) P5 port.

Connect the solenoid valve (13) G port and manifold (*2) P5 port with the assembly hose (3/P6).

CZPI3R-270

8

3 - 32 EN

3 - ASSEMBLY

6.

Install the hose adapter (17) on the solenoid valve (13) A1 port.

CZPI3R-271

7.

8.

9

Install the elbow (4) on the control valve (*3) pbr2 port.

Connect the solenoid valve (13) A1 port and control valve (*3) pbr2 port with the assembly hose (3/Y7), and then fasten with the 2 wire bands (5).

Tighten the assembly hose (3/Y7) together with the pilot control line (*4).

CZPI3R-272

10

CZPI3R-273

11

Install the hose adapter (17) on the solenoid valve (13) A2 port.

3 - 33 EN

3 - ASSEMBLY

9.

10.

Install the elbow (2) on the control valve (*3) par2 port.

Connect the solenoid valve (13) A2 port and control valve (*3) par2 port with the assembly hose (3/Y6).

CZPI3R-274

12

CZPI3R-275

13

Install the plug (12) on the solenoid valve (13) P port.

3 - 34 EN

3 - ASSEMBLY

11.

Fasten the assembly hoses at 3 locations with 1 wire band (5) each, 1 mount clamp (7) each, and 1 Phillips pan head screw (8) each as in the diagram.

Fasten the assembly hoses (3/Y6) (3/Y7) with the wire bands (5).

CZPI3R-276

14

3 - 35 EN

3 - ASSEMBLY

Sensing system - Install (Harness) CX210C NA

BOZQCU-086

1.

1

Route the wire harness (1), and then connect the harness (red tape) (*5) of the wire harness (1) to the under side connector of the solenoid valve (13), and connect the harness (blue tape) (*6) to the upper side connector.

BOZQCU-087

2

3 - 36 EN

3 - ASSEMBLY

2.

3.

Fasten the wire harness (1) at 3 locations with 1 wire band (5) each, 1 mount clamp (7) each, and 1 Phillips pan head screw (8) each.

BOZQCU-088

3

BOZQCU-089

4

Fasten the wire harness (1) with 2 wire bands (5), 1 mount clamp (7), and 1 Phillips pan head screw (8).

3 - 37 EN

3 - ASSEMBLY

4.

5.

Fasten the 2 couplers along the wire harness (1) with 1 clip (18) each and 1 sems bolt (19) each.

BOZQCU-090

5

BOZQCU-091

6

Extend the wire harness (1) to the floor (*1) side from under the cab and connect to the cab main harness (*7).

Fasten the wire harness (1) with the 2 wire bands (5).

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

3 - 38 EN

3 - ASSEMBLY

Safety sign - Install (Inside cab) CX210C NA

ORS6Q1-024

1.

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

2.

Attach the operation label (switch control) (7).

1

3 - 39 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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