CNH Second option circuit kit (proportional control) CX160D Crawler excavator Instructions Manual

INSTALLATION INSTRUCTIONS

KG0LP427-00

SECOND OPTION CIRCUIT KIT (PROPORTIONAL CONTROL)

APPROXIMATE INSTALLATION TIME: 20.0 hours

San - 47891694 Issue date July 2015 EN

KG0LP427-00 - SECOND OPTION CIRCUIT KIT (PROPORTIONAL CONTROL) CASE CONSTRUCTION CX160D

San - 47891694 Issue date July 2015 EN

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

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

3 ASSEMBLY SECOND OPTION CIRCUIT (PROPORTIONAL CONTROL) Installation of hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Installation of control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Boom line installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Upper main line installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Pilot line installation - Proportional control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Harness installation - Proportional control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Control lever installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Attachment of plate inside cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

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 3-26) Item 75

Description Knob (left–hand) proportional control

Quantity 1

Part Reference KHJ28540

Quantity 2 2 1 1 1

Part Reference 108R010Y030R KEH0114 KNJ19600 UCD0096 KNJ14070

Quantity 1 3 2

Part Reference KNJ14210 UBJ0157 BHJ0795

Quantity 1 5 1 1 1 1 1 1 1 1 1 2 1 4 1 1 1 2 1 1 1 1

Part Reference KLJ14470 KHH0142 KLJ14460 KLJ14480 KNJ0604 KHJ0345 KSJ2723 KHJ1044 KNJ13150 KAJ2179 KLJ14500 KRJ11580 KNJ13200 105R010Y030R KHJ0352 KHJ28600 KNJ20610 105R008Y020R KHJ2021 KHJ2025 105R010Y025R KAJ2432

Quantity 1 – 1 1

Part Reference KHJ1178 KLJ15100 KHJ25060 KHJ18960

Hydraulic Pump (Refer to 3-1) Item 4 5 6 7 9

Description Hexagon socket head bolt M10x30 High-strength washer M10 second option gear pump O-ring Power take-off for gear pump

Control Valve (Refer to 3-3) Item 1 3 4

Description Add-on second option control valve O-ring O-ring

Second Option Main Circuit (Refer to 3-11) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Description Hydraulic hose Wire band L = 250 Hydraulic hose Hydraulic hose Hose adapter G1/2 Elbow G1 Hydraulic hose Long elbow G1/2 Hydraulic hose Hose adapter G1/2 Bracket Hose clamp Plate Sems bolt M10x30 Elbow G1 Elbow Bracket Sems bolt M8x20 Hose clamp Clamp Sems bolt M10x25 Hose adapter

second Option Pilot Circuit Proportional Control (Refer to 3-17) Item 1 2 2-1 2-2

Description Long elbow G1/4 Assembly hose 2-1 - 2-4 Nylon hose Nylon hose

1-1 EN

1 - KIT CONTENT

Item 2-3 2-4 3 4 6 7 8 9 11 12 13 18 19 20 21 22 23 24

Description Nylon hose Nylon hose Wire band L = 250 Elbow G1/4 Mount clamp Phillips pan head screw M6x8 Hose adapter G1/4 Wire band L = 300 Nipple with filter G1/4 Sems bolt M10x20 Bracket Wire band L = 380 Clamp with band M8 Clamp with band M8 Sems bolt M8x16 Pressure switch Reducing valve Tee G1/4

Quantity 1 1 12 1 2 2 3 4 1 2 1 3 1 1 2 2 1 2

Part Reference KHJ2089 KHJ2088 KHH0142 KHJ28580 KHR0319 145N006S008R KNJ0758 KHH0143 CNA0584 105R010Y020R KHJ28770 KAR0017 KHR2584 KHR2581 105R008Y016R KHR21490 MFJ71500 KAJ3807

Quantity 1 – 2 2

Part Reference KHR40410 KHH0142 KHR1957 KHR1253

Quantity 1

Part Reference KHP27250

Quantity 5 20 2 14 2 5 2 1

Part Reference KHV10480 105R012Y030R KNV13810 105R012Y060R KNV13820 KHV10500 KLV12340 KLV12310

Quantity 3 1 2 1 1 1

Part Reference KHJ0480 KLV12460 KLV12450 KLV12430 KLV14190 KLV14180

Electrical part (Refer to 3-23) Item 64 65 66 67

Description Wire harness Wire band L = 250 Clip Bolt M6x16

Plate (Refer to 3-30) Item 72

Description Operation label (proportional control)

Clamp (Refer to 3-5) Item 1 2 3 4 5 6 14 16

Description Pipe clamp Sems bolt M12x30 Seating (boom top left) Sems bolt M12x60 Seating (boom top right–hand) Pipe clamp Seating (boom center HBCV + second option) Seating (boom foot HBCV + second option)

Boom Line (Refer to 3-5) Item 7 8 9 10 11 12

Description Plug Line assembly (right–hand) Line assembly (left-hand and drain) Line assembly (right–hand) Line assembly (drain) Line assembly (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 ( 13 mm, 17 mm, 19 mm, 27 mm, 36 mm, 41 mm) • Box wrenches ( 13 mm, 17 mm, 19 mm, 27 mm, 36 mm, 41 mm) • Hexagon wrenches ( 8 mm) • Phillips screwdriver (No. 3) • 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 SECOND OPTION CIRCUIT (PROPORTIONAL CONTROL)

Installation of hydraulic pump 1. Install the power take-off (9) for the gear pump on the hydraulic pump (*1) with the four bolts (*3).

• The bolts (*3) are accessories for the power take-off (9) for the gear pump.

SMIL15CEX8145BB

1

3-1 EN

3 - ASSEMBLY

2. Set the O-ring (7) on the second option gear pump (6), and install with two hexagon socket head bolts (4) and two high-strength washers (5).

• Tightening torque: 26.995 lb ft)

30.6 - 36.6 N·m (22.569 -

• After installing the second option gear pump (6), bleed off air using the air bleed port (*2). (See the Service Manual.)

SMIL15CEX8146BB

2

3-2 EN

3 - ASSEMBLY

Installation of control valve

SMIL15CEX8147FB

1

1. Set the three O-rings (3) and two O-rings (4) on the control valve (*1).

SMIL15CEX8148AB

2

3-3 EN

3 - ASSEMBLY

2. Install the add-on second option control valve (1) on the control valve (*1) with the two hexagon socket head bolts (1a) and two hexagon socket head bolts (1b).

• Tightening torque: 45 - 55 N·m (33.190 - 40.566 lb ft) • The hexagon socket head bolts (1a) and hexagon socket head bolts (1b) are accessories for the add-on second option control valve.

Install the high-strength bolt (*2) on the control valve (*1).

SMIL15CEX8149BB

3

3-4 EN

3 - ASSEMBLY

Boom line installation

SMIL15CEX8150FB

1

Line Assembly (drain) (11) and Line Assembly (left) (12) 1. Set the line assembly (drain) (11) and line assembly (left) (12).

SMIL15CEX8151BB

2

3-5 EN

3 - ASSEMBLY

2. Fasten the seating (boom foot HBCV + second option) (16) with the two sems bolts (4).

Fasten the line assembly (drain) (11) and line assembly (left) (12) with one pipe clamp (1) and two sems bolts (2).

• Fasten the pipe clamp (1) at a position 80 mm (3.150 in) from the rear end of the line assembly (drain) (11).

SMIL15CEX8152AB

3

SMIL15CEX8153AB

4

SMIL15CEX8154BB

5

3. Fasten the seating (boom center HBCV + second option) (14) at two locations with the two sems bolts (4) each.

Fasten the line assembly (drain) (11) and line assembly (left) (12) at two locations with the one pipe clamp (1) each and the two sems bolts (2) each.

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

Fasten the line assembly (drain) (11) and line assembly (left) (12) with one pipe clamp (1) and two sems bolts (2).

• Fasten the pipe clamp (1) at a position 140 mm (5.512 in) from the front end of the line assembly (left) (12) and at a position 130 mm (5.118 in) from the front end of the line assembly (drain) (11).

3-6 EN

3 - ASSEMBLY

Line Assembly (right) (10) 1. Set the line assembly (right) (10).

SMIL15CEX8155BB

6

SMIL15CEX8156AB

7

SMIL15CEX8157AB

8

2. Fasten the line assembly (right) (10) with one pipe clamp (6) and two sems bolts (2).

• Fasten the pipe clamp (6) at a position 80 mm (3.150 in) from the rear end of the line assembly (right) (10).

3. Fasten the line assembly (right) (10) at two locations with the one pipe clamp (6) each and the two sems bolts (2) each.

3-7 EN

3 - ASSEMBLY

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

Fasten the line assembly (right) (10) with one pipe clamp (6) and two sems bolts (2).

• Fasten the pipe clamp (6) at a position 140 mm (5.512 in) from the front end of the line assembly (right) (8).

SMIL15CEX8158BB

9

Line Assemblies (left and drain) (9) 1. Set the two line assemblies (left and drain) (9) and connect with the line assembly (drain) (11) and line assembly (left) (12).

SMIL15CEX8159BB

10

3-8 EN

3 - ASSEMBLY

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

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

• Fasten the pipe clamp (1) at a position 96 mm (3.780 in) from the front end of the line assembly (left and drain) (9).

SMIL15CEX8160BB

11

SMIL15CEX8161BB

12

Line Assembly (right) (8) 1. Set the line assembly (right) (8) and connect to the line assembly (right) (10).

3-9 EN

3 - ASSEMBLY

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

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

• Fasten the pipe clamp (6) at a position 96 mm (3.780 in) from the end of the line assembly (right) (8).

SMIL15CEX8162BB

13

SMIL15CEX8163BB

14

Plug (7) Installation 1. Install the three plugs (7) at the front end of the line.

3-10 EN

3 - ASSEMBLY

Upper main line installation

SMIL15CEX8164FB

1

1. Install the hose adapter (5) on the hydraulic tank (*1) and connect the hydraulic hose (1).

SMIL15CEX8165AB

2

SMIL15CEX8166AB

3

2. Connect the hydraulic hose (1) to the boom line (*3).

3-11 EN

3 - ASSEMBLY

3. Install the hose adapter (10) on the control valve (*2) 4B7 port and connect the hydraulic hose (4).

SMIL15CEX8167BB

4

SMIL15CEX8168AB

5

4. Connect the hydraulic hose (4) to the boom line (*5).

3-12 EN

3 - ASSEMBLY

5. Install the long elbow (8) at the control valve (*2) 4A7 port and connect the hydraulic hose (3).

SMIL15CEX8169BB

6

SMIL15CEX8170AB

7

6. Connect the hydraulic hose (3) to the boom line (*4).

3-13 EN

3 - ASSEMBLY

7. Install the bracket (11) on the housing frame (*6) with two sems bolts (14).

Set the hydraulic hoses (1) (3) (4) on the two hose clamps (12) and fasten with the plate (13) and two sems bolts (14).

• Install the hose clamps (12) with the surfaces with protrusions both facing the left side.

• Fasten the hydraulic hoses so that the length from the front end of the hose (boom side) to the hose clamps (12) is 970 mm (38.189 in).

SMIL15CEX8171BB

8

SMIL15CEX8172AB

9

8. Fasten the hydraulic hoses (1) (3) with three wire bands (2) so that the lengths from the front end of the hose (boom side) to each wire band (2) are 600 mm (23.622 in), 450 mm (17.717 in), and 920 mm (36.220 in).

Fasten the hydraulic hoses (3) (4) with one wire band (2) so that the length from the front end of the hose (boom side) to the wire band (2) is 780 mm (30.709 in).

Fasten the hydraulic hoses (1) (3) (4) with one wire band (2).

9. Install the elbow (6) on the suction line. Install the elbow (15) on the hydraulic pump (*7) and connect the hydraulic hose (7).

SMIL15CEX8173AB

10

3-14 EN

3 - ASSEMBLY

10. Install the elbow (16) on the hydraulic pump (*7) and connect the hydraulic hose (9).

SMIL15CEX8174AB

11

SMIL15CEX8175CB

12

11. Install the hose adapter (22) on the control valve (*2) P3 port and connect the hydraulic hose (9).

Fasten the hydraulic hose (9) with the clamp (*10).

• Fasten so that the distance between the hydraulic pump (*7) and clamp (*10) is 660 mm (25.984 in).

3-15 EN

3 - ASSEMBLY

12. Install the bracket (17) on the hydraulic tank with two sems bolts (18).

Set the hose clamp (19) and clamp (20) on the hydraulic hose (9) and fasten with the sems bolt (21).

SMIL15CEX8176AB

13

3-16 EN

3 - ASSEMBLY

Pilot line installation - Proportional control

SMIL15CEX7904FB

1

SMIL15CEX7905FB

2

3-17 EN

3 - ASSEMBLY

SMIL15CEX7906FB

3

*2. Manifold *3. Control valve 1. Install the reducing valve (23) on the bracket (13) with two sems bolts (21).

Install the bracket (13) on the floor (*1) with two sems bolts (12).

SMIL15CEX7907AB

4

SMIL15CEX7908AB

5

2. Install the hose adapter (8) on the reducing valve (23) T port.

3-18 EN

3 - ASSEMBLY

3. Install the hose adapter (8) or the tee (5) on the manifold (*2) T5 port.

Connect the reducing valve (23) P port and manifold (*2) T5 port with the nylon hose (2-4).

SMIL15CEX7909BB

6

SMIL15CEX7910AB

7

4. Install the nipple with filter (11) on the reducing valve (23) P port.

3-19 EN

3 - ASSEMBLY

5. Install the hose adapter (8) or the tee (5) on the manifold (*2) P5 port.

Connect the reducing valve (23) P port and manifold (*2) P5 port with the nylon hose (2-3).

SMIL15CEX7911BB

8

SMIL15CEX7912AB

9

6. Install the tee (24) and pressure switch (22) on the reducing valve (23) A1 port.

3-20 EN

3 - ASSEMBLY

7. Install the long elbow (1) on the control valve (*3) 4b5 port.

Connect the reducing valve (23) A1 port and control valve (*3) 4b5 port with the nylon hose (2-2), and then fasten with the wire band (3).

• Fasten the nylon hose (2-2) together with the pilot P and T lines (*5).

SMIL15CEX7913BB

10

SMIL15CEX7914AB

11

SMIL15CEX7915AB

12

8. Install the tee (24) and pressure switch (22) on the reducing valve (23) A2 port.

9. Install the elbow (4) on the control valve (*3) 4a5 port.

Connect the reducing valve (23) A2 port and control valve (*3) 4a5 port with the nylon hose (2-1), and then fasten with the wire band (3).

• Fasten the nylon hose (2-1) together with the pilot control line (*4).

• Install the elbow (4) with the horizontal angle of 55° down.

3-21 EN

3 - ASSEMBLY

10. Fasten the nylon hose with three wire bands (3), two mount clamps (6), and two Phillips pan head screws (7) as shown in the diagram.

Fasten the nylon hose with four wire bands (9).

SMIL15CEX8991BB

13

SMIL15CEX8686AB

14

SMIL15CEX8876AB

15

11. Fasten the nylon hose with two wire bands (3), three wire bands (18), and clamp with band (19).

12. Fasten the nylon hose with the wire band (3), wire band (18), and clamp with band (20).

3-22 EN

3 - ASSEMBLY

Harness installation - Proportional control

SMIL15CEX2670FB

1

SMIL15CEX2671FB

2

3-23 EN

3 - ASSEMBLY

1. Connect the wire harness (64) and reducing valve (*1).

Fasten the two couplers on the wire harness (64) with one clip (66) each and one bolt (67) each.

SMIL15CEX2672AB

3

SMIL15CEX2673BB

4

SMIL15CEX2674AB

5

2. Route the wire harness (64) as shown in the diagram.

Fasten the wire harness (64) at four locations with four wire bands (65).

3. Connect the wire harness (64) connector (8-pin) to the frame main harness (*2) and fasten with the wire band (65).

3-24 EN

3 - ASSEMBLY

4. Extend the wire harness (64) to the floor side from under the cab.

Connect the wire harness (64) connector (16-pin) to the cab main harness and fasten with the wire band (65).

SMIL15CEX2675AB

6

3-25 EN

3 - ASSEMBLY

Control lever installation 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.

3-26 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).

3-27 EN

3 - ASSEMBLY

Installation of control lever (left) 1. After installing the knob (left) (75), 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: 38.3 - 44.1 N·m (28.2 32.5 lb ft)

SMIL14II01652AB

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).

3-28 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).

3-29 EN

3 - ASSEMBLY

Attachment of plate inside cab

SMIL15CEX8178GB

1

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

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

3-30 EN

Index ###_Index_###

A Attachment of plate inside cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 B Boom line installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5

C Control lever installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 H Harness installation - Proportional control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 I Installation of control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation of hydraulic pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3 3-1

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

1-1

P Pilot line installation - Proportional control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 U Upper main line installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-11

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