CNH Second option line proportional control kit CX250D Crawler excavator Instructions Manual

INSTALLATION INSTRUCTIONS

KG1BP450-00

SECOND OPTION LINE PROPORTIONAL CONTROL KIT

APPROXIMATE INSTALLATION TIME: 20.0 hours

San - 47789093 Issue date March 2015 EN

KG1BP450-00 - SECOND OPTION LINE PROPORTIONAL CONTROL KIT CASE CONSTRUCTION CX250D

San - 47789093 Issue date March 2015 EN

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

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

3 ASSEMBLY 2nd OPTION CIRCUIT PROPORTIONAL CONTROL Installation of hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Installation of control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Boom line installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Upper main line installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Pilot line installation - proportional control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Harness installation - Proportional control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Control lever installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Installation of nameplate 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 (left) (Refer to 3-21) Item 75

Description Knob (left) proportional control

Quantity 1

Part Reference KHJ28540

Quantity 1 1 1 2 2

Part Reference KRJ12620 KRJ34770 UCD0096 108R010Y030R KEH0114

Quantity 1

Part Reference KRJ10330

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

Part Reference KUJ10310 KHJ24380 KHH0142 KHJ21550 KHJ28600 KBJ24900 KAJ2432 KHJ0642 KHJ1778 KBJ19690 KBJ19700 KBJ22590 KBJ19730 105R010Y025R KRJ11580 KRJ11590 KHJ23010 KNJ0604 KHJ1300

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

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

Control valve (Refer to 3-2) Item 13

Description Add-on second option control valve

Second double-acting main circuit (Refer to 3-8) Item 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 50 55 56

Description Hydraulic hose Long elbow Wire band (L = 250) Hose clamp Elbow Hydraulic hose Hose adapter Elbow G3/4 x G1/2 Hose adapter G3/4 x G1/2 Hydraulic hose Hydraulic hose Hydraulic hose Bracket Sems bolt M10x25 Hose clamp Bracket Tee G3/4 x G1 x G1 Hose adapter G1/2 Tee

Second Double-acting pilot circuit proportional control (Refer to 3-13) Item 36 37 38 39 40 41

Description Reducing valve Sems bolt M8x16 Bracket Sems bolt M10x20 Tee G1/4 Nipple with filter G1/4

Quantity 1 2 1 2 2 1

Part Reference MFJ71500 105R008Y016R KHJ28770 105R010Y020R KAJ3807 CNA0584

1-1 EN

1 - KIT CONTENT

Item 42 43 44 45 46 47 48 51 52 53 54

Description Hose adapter G1/4 Assembly hose Stud G1/4 Elbow G1/4 Wire band (L = 250) Pressure switch Wire band (L = 300) Hose adapter G1/4 Mount clamp Phillips pan head screw M6x8 Wire band (L = 250)

Quantity 1 1 1 2 4 2 8 2 2 2 3

Part Reference KNJ0758 KBJ22340 KHJ13640 KHJ28580 KHH0142 KHR21490 KHH0143 KNJ0758 KHR0319 145N006S008R KHH0142

Quantity 1 2 2

Part Reference KHR40410 KHH0142 KHR1957 KHR1253

Quantity 1

Part Reference KHP27250

Quantity 1 6 6 16 18 2 3 3 2

Part Reference KRV20290 KHV10480 KHV10500 105R012Y030R 105R012Y060R KRV20300 KNV13810 KNV13820 KHV11640

Description (left-hand) (left-hand) (right-hand) (right-hand) (drain) (drain)

Quantity 1 1 1 1 1 1

Part Reference KBV31250 KBV23660 KBV31260 KBV23680 KBV31250 KBV23690

Description

Quantity 3

Part Reference KHJ0480

Electrical part (Refer to 3-18) Item 64 65 66 67

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

Plate (Refer to 3-25) Item 72

Description Operation label (switch control)

Clamp (Refer to 3-3) Item 68 69 70 71 72 73 83 84 90

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

Boom line (Refer to 3-3) Item 101 102 103 104 105 106

Line Line Line Line Line Line

assembly assembly assembly assembly assembly assembly

Plug (Refer to 3-3) Item 108

Plug G1/2

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, 27 mm) • Box Wrenches ( 13 mm, 17 mm, 19 mm, 22 mm, 27 mm) • 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.

SMIL14II01743AA

1

SMIL14II01744AB

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.

SMIL14II01745BB

3

SMIL14II01746AB

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 2nd OPTION CIRCUIT PROPORTIONAL CONTROL

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

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

SMIL15CEX3046AB

1

SMIL15CEX3047AB

2

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

• Tightening torque: 30.0 - 36.6 N·m (22.1 - 27.0 lb ft).

Install the second option gear pump (4), and then bleed off air using the air bleed port (*2). (See the Service Manual.)

3-1 EN

3 - ASSEMBLY

Installation of control valve 1. Install the add-on 2nd option control valve (13) on the control valve (*1) with the four nuts (1a) and four tie rods (1b).

• Tightening torque: 116 - 128 N·m (1027 - 1133 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 second option control valve.

SMIL15CEX3048BB

1

3-2 EN

3 - ASSEMBLY

Boom line installation Line installation

SMIL15CEX2626FB

1

Line Assembly (left-hand) (102) and Line Assembly (drain) (106) 1. Set the line assembly (left) (102) and line assembly (drain) (106).

SMIL15CEX2627AB

2

3-3 EN

3 - ASSEMBLY

2. Fasten the seating (boom foot second option) (68) with two sems bolts (72).

Fasten the line assembly (left) (102) and line assembly (drain) (106) with one pipe clamp (69) and two sems bolts (71).

• Fasten the pipe clamp (69) at a position 180 mm (7.1 in) from the rear ends of the line assembly (left) (102) and the line assembly (drain) (106).

SMIL15CEX2628AB

3

SMIL15CEX2629AB

4

SMIL15CEX2630AB

5

3. Fasten the seating (boom center second option) (73) at two locations with two sems bolts (72) each.

Fasten the line assembly (left) (102) and line assembly (drain) (106) at two locations with one pipe clamp (69) each and two sems bolts (71) each.

4. Fasten the seating (boom top left) (83) with two sems bolts (72) each.

Fasten the line assembly (left) (102) and line assembly (drain) (106) with one pipe clamp (69) and two sems bolts (*1).

• Fasten the pipe clamp (69) at a position 124 mm (4.9 in) from the front end of the line assembly (left) (102).

• Fasten the pipe clamp (69) at a position 110 mm (4.3 in) from the end of the line assembly (drain) (106).

3-4 EN

3 - ASSEMBLY

Line assembly (104) (right-hand) 1. Set the line assembly (right) (104).

SMIL15CEX2631AB

6

SMIL15CEX2632AB

7

SMIL15CEX2633AB

8

SMIL15CEX2634AB

9

2. Refasten the line assembly (right) (104) with one pipe clamp (70) and two sems bolts (71).

• Fasten the pipe clamp (70) at a position 180 mm (7.1 in) from the rear end of the line assembly (right) (104).

3. Fasten the line assembly (right) (104) at two locations with one pipe clamp (70) each and two sems bolts (71) each.

4. Fasten the seating (boom top right) (84) with two sems bolts (72) each.

Fasten the line assembly (right) (104) with one pipe clamp (70) and two sems bolts (*1) each.

• Fasten the pipe clamp (70) at a position 110 mm (4.3 in) from the front end of the line assembly (right) (104).

3-5 EN

3 - ASSEMBLY

Line assembly (101) (left-hand) and line assembly (drain) (105) 1. Set the line assembly (left) (101) and the line assembly (drain) (105), and connect with the line assembly (left) (102) and the line assembly (drain) (106) respectively.

SMIL15CEX2635AB

10

SMIL15CEX2636AB

11

SMIL15CEX2637AB

12

SMIL15CEX2638AB

13

2. Fasten the seating (boom top left) (83) with two sems bolts (72).

Fasten the line assembly (left) (101) and line assembly (drain) (105) with one pipe clamp (69) and two sems bolts (*1).

• Fasten the pipe clamp (69) at a position 100 mm (3.9 in) from the front ends of the line assembly (left) (101) and the line assembly (drain) (105).

3. Fasten the line assembly (left) (101) and line assembly (drain) (105) to the seating (boom top left) (83) with one pipe clamp (70) and two sems bolts (71).

• Fasten at a position 500 mm (19.7 in) forward of the rear side seating (boom top left) (83).

Fasten the seating (boom top left) (83) to the line (*2) with one pipe clamp (90) and two sems bolts (72).

Line assembly (right-hand) (103) 1. Set the line assembly (right) (103) and connect to the line assembly (right) (104).

3-6 EN

3 - ASSEMBLY

2. Fasten the seating (boom top right) (84) with two sems bolts (72).

Fasten the line assembly (right) (103) with one pipe clamp (69) and two sems bolts (*1).

• Fasten the pipe clamp (69) at a position 100 mm (3.9 in) from the front end of the line assembly (right).

SMIL15CEX2639AB

14

SMIL15CEX2640AB

15

SMIL15CEX2641BB

16

3. Fasten the line assembly (right) (103) to the seating (boom top right) (84) with one pipe clamp (70) and two sems bolts (71).

• Fasten at a position 500 mm (19.7 in) forward of the rear side seating (boom top right) (84).

Fasten the seating (boom top right) (84) to the line (*2) with one pipe clamp (90) and two sems bolts (72).

Plug (108) installation 1. Install the three plugs (108) at the front end of the line.

3-7 EN

3 - ASSEMBLY

Upper main line installation Main line installation

SMIL15CEX2642FB

1

1. Install the elbow (21) on the control valve (*2) AR2 port.

SMIL15CEX2643BB

2

3-8 EN

3 - ASSEMBLY

2. Connect the control valve (*2) and line assembly (*4) with the hydraulic hose (23).

SMIL15CEX2644AB

3

SMIL15CEX2645BB

4

SMIL15CEX2646AB

5

3. Install the hose adapter (22) on the control valve (*2) BR2 port.

4. Connect the control valve (*2) BR2 port and the line assembly (*5) with the hydraulic hose (24).

3-9 EN

3 - ASSEMBLY

5. Install the hose adapter (55) or tee (56) on the hydraulic tank (*1).

SMIL15CEX2647AB

6

SMIL15CEX2648AB

7

6. Connect the hydraulic tank (*1) T port and the line assembly (*3) with the hydraulic hose (25).

3-10 EN

3 - ASSEMBLY

7. Install the bracket (26) on the housing frame (*6) with two sems bolts (27).

Sandwich the hydraulic hoses (23), (24), (25) with two hose clamps (28), and then sandwich the hose clamps (28) with the bracket (26) and bracket (29) and fasten with two sems bolts (27).

• Install the hose clamps (28) with the surfaces with protrusions (*a) facing inside the vehicle body.

• Fasten the hose clamps (28) at a position 880 mm (34.6 in) from the front end (boom side) of the hydraulic hoses (23), (24), (25).

Fasten the hydraulic hose with the wire band (16).

SMIL15CEX2649CB

8

SMIL15CEX2650AB

9

8. Fasten the hydraulic hoses (23), (24), (25) with three wire bands (16).

• Fasten the wire bands (16) at a position 380 mm (15.0 in) and 680 mm (26.8 in) from the front end (boom side) of the hydraulic hoses (23), and (25).

• Fasten the wire bands (16) at a position 530 mm (20.9 in) from the front end (boom side) of the hydraulic hoses (23), and (24).

3-11 EN

3 - ASSEMBLY

9. Install the hose adapter (20) on the control valve (*2) Pr port.

SMIL15CEX2651AB

10

SMIL15CEX2652AB

11

SMIL15CEX2653AB

12

SMIL15CEX2654AB

13

10. Install the elbow (18) on the hydraulic pump (*7).

Connect the control valve (*2) Pr port and hydraulic pump (*7) with the hydraulic hose (19).

11. Remove the plate (*8) with two sems bolts (*9).

Set the hose clamp (*10) on the hydraulic hose (19), and fasten the plate (*8) with the sems bolt (*9).

• Fasten the hose clamp (*10) at a position 680 mm (26.8 in) from the front end (hydraulic pump side) of the hydraulic hose (19).

12. Install the long elbow (15) on the hydraulic pump (*7).

Install the tee (50) on the suction line (*11).

Connect the hydraulic pump (*7) and the suction line (*11) with the hydraulic hose (14).

Set the hose clamp (17) on the hydraulic hose (14) and fasten the hydraulic hose (14) with the wire band (16).

• Fasten the hydraulic hose (14) together with the pilot P and T lines.

3-12 EN

3 - ASSEMBLY

Pilot line installation - proportional control

SMIL15CEX2655FB

SMIL14II01635FB

1

2

3-13 EN

3 - ASSEMBLY

SMIL15CEX2656FB

a. Hose assembly b. Code *1. Floor

*2. *3.

3

Manifold Control valve

1. Install the reducing valve (36) on the bracket (38) with two sems bolts (37).

Install the bracket (38) on the floor (*1) with two sems bolts (39).

SMIL15CEX2657AB

4

SMIL15CEX2658AB

5

2. Install the hose adapter (42) on the reducing valve (36) T port.

• Tightening torque: 25.4 - 31.4 N·m (18.7 - 23.2 lb ft)

3-14 EN

3 - ASSEMBLY

3. Install the hose adapter (51) at the manifold (*2) T5 port.

Connect the reducing valve (36) T port and manifold (*2) T5 port with the assembly hose (43) (T6).

SMIL15CEX2659AB

6

SMIL15CEX2660AB

7

SMIL15CEX2661AB

8

SMIL15CEX2662AB

9

4. Install the nipple with filter (41) on the reducing valve (36) P port.

• Tightening torque: 25.4 - 31.4 N·m (18.7 - 23.2 lb ft)

5. Install the hose adapter (51) at the manifold (*2) P5 port.

Connect the reducing valve (36) P port and manifold (*2) P5 port with the assembly hose (43) (P6).

6. Install the tee (40) on the reducing valve (36) A1 port.

• Tightening torque: 25.4 - 31.4 N·m (18.7 - 23.2 lb ft)

3-15 EN

3 - ASSEMBLY

7. Install the elbow (45) on the control valve (*3) pbr1 port.

Connect the reducing valve (36) A1 port and control valve (*3) pbr1 port with the assembly hose (43) (Y7).

SMIL15CEX2663BB

10

SMIL15CEX2664AB

11

8. Install the tee (40) on the reducing valve (36) A2 port.

• Tightening torque: 25.4 - 31.4 N·m (18.7 - 23.2 lb ft)

3-16 EN

3 - ASSEMBLY

9. Install the stud (44) and elbow (45) on the control valve (*3) par1 port.

Connect the reducing valve (36) A2 port and control valve (*3) par1 port with the assembly hose (43) (Y6).

Fasten the assembly hose (43) (Y6) with three wire bands (46).

SMIL15CEX2668BB

12

SMIL15CEX2669BB

13

10. Fasten the assembly hose that comes out from the reducing valve (36) at two locations with one mount clamp (52) each, one Phillips pan head screw (53) each, and one wire band (54) each.

Fasten the assembly hose that comes out from the reducing valve (36) with the wire band (54).

Install the pressure switch (47) on the reducing valve (36).

3-17 EN

3 - ASSEMBLY

Harness installation - Proportional control

SMIL15CEX2670FB

1

SMIL15CEX2671FB

2

3-18 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).

3-19 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

3-20 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.

3-21 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).

3-22 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).

3-23 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).

3-24 EN

3 - ASSEMBLY

Installation of nameplate inside cab Plate attachment

SMIL14II01651GB

1

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

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

3-25 EN

3 - ASSEMBLY

3-26 EN

Index ###_Index_###

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

3-3

C Control lever installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 H Harness installation - Proportional control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 I Installation of control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Installation of hydraulic pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Installation of nameplate inside cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 K Kit content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

P Pilot line installation - proportional control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 U Upper main line installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8

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