CNH Second option line proportional control (plus option one) CX210D Excavator Instructions ManuAL

INSTALLATION INSTRUCTIONS

KG2RP464-00

SECOND OPTION LINE PROPORTIONAL CONTROL KIT (PLUS OPTION ONE)

APPROXIMATE INSTALLATION TIME: 20.0 hours

San - 48010296 Issue date May 2016 EN

KG2RP464-00 - SECOND OPTION LINE PROPORTIONAL CONTROL KIT (PLUS OPTION ONE) CASE CONSTRUCTION CX210D

San - 48010296 Issue date May 2016 EN

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

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

3 ASSEMBLY SECOND OPTION CIRCUIT KIT (PROPORTIONAL CONTROL) (PLUS OPTION 1) 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Harness installation - Proportional control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 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 7 1 1 1 1 1 1 1 1 1 1 4 2 1 2

Part Reference KRJ40700 KHJ1713 KHH0142 KHJ2021 KHJ28600 KBJ22210 KHJ28650 KHJ0642 KHJ1778 KBJ12420 KBJ12440 KRJ37650 KBJ19730 105R010Y025R KRJ11580 KRJ11590 KHJ0352

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

Description Hydraulic hose Stud G1/2x44 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 Elbow G1

Second double-acting pilot circuit proportional control (Refer to 3-14) Item 36 37 38 39 40 41 42 43

Description Reducing valve Sems bolt M8x16 Bracket Sems bolt M10x20 Tee G1/4 Nipple with filter G1/4 Hose adapter G1/4 Assembly hose ( 43–1 to 43–4)

Quantity 1 2 1 2 2 1 1

Part Reference MFJ71500 105R008Y016R KHJ28770 105R010Y020R KAJ3807 CNA0584 KNJ0758 KBJ22340

1-1 EN

1 - KIT CONTENT

Item 43–1 43–2 43–3 43–4 44 45 46 47 48 51 53

Description

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

Part Reference KHJ17840 KHJ16300 KHJ2089 KHJ2088 KHJ13640 KHJ28580 KHH0142 KHR21490 KHH0143 KHJ0869 KHR10220

Quantity 1 2 2

Part Reference KHR39520 KHH0142 KHR1957 KHR1253

Quantity 1 1

Part Reference KHP27240 KHP27250

Quantity 1 6 6 16 18 2 3 3 2

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

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

Quantity 1 1 2 1 1

Part Reference KRV40190 KRV42280 KRV40180 KRV32710 KRV32720

Description

Quantity 3

Part Reference KHJ0480

Nylon hose Y6 Nylon hose Y7 Nylon hose P6 Nylon hose T6 Stud G1/4 Elbow G1/4 Wire band (L = 250) Pressure switch Wire band (L = 300) Tee G1/4 Mount clamp

Electrical part (Refer to 3-19) Item 78 79 80 81

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

Plate (Refer to 3-25) Item 72 73

Description Operation label (proportional control) 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 101 102 103 104 106

Line Line Line Line Line

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, 36 mm, 41 mm) • Box Wrenches ( 13 mm, 17 mm, 19 mm, 22 mm, 27 mm, 36 mm, 41 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 SECOND OPTION CIRCUIT KIT (PROPORTIONAL CONTROL) (PLUS OPTION 1)

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 second 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

SMIL15CEX2866FB

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 170 mm (6.7 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 84 mm (3.3 in) from the front end of the line assembly (left) (102).

• Fasten the pipe clamp (69) at a position 65 mm (2.6 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 107 mm (4.2 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 84 mm (3.3 in) from the front end of the line assembly (right) (104).

3-5 EN

3 - ASSEMBLY

Line assembly (103) (left-hand) 1. Set the two line assemblies (left) (103), and connect with the line assembly (left) (102) and the line assembly (drain) (106) respectively.

SMIL15CEX2635AB

10

SMIL15CEX2636AB

11

SMIL15CEX2867AB

12

SMIL15CEX3023AB

13

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

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

• Fasten the pipe clamp (69) at a position 58 mm (2.3 in) from the front ends of the line assembly (left) (103).

3. Fasten the two line assemblies (left) (103) 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) (101) 1. Set the line assembly (right) (101) 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) (101) with one pipe clamp (69) and two sems bolts (*1).

• Fasten the pipe clamp (69) at a position 58 mm (2.3 in) from the front end of the line assembly (right).

SMIL15CEX3024AB

14

SMIL15CEX3025AB

15

SMIL15CEX2641BB

16

3. Fasten the line assembly (right) (101) 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.

• Fasten the elbow (21) with the horizontal angle of about 15 °.

66610E82

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. Check that the hose adapter (*55) is installed on the hydraulic tank (*1).

209A55DA

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).

Set the two hose clamps (28) on the hydraulic hoses (23), (24), (25), and then set the bracket (26) and bracket (29) on the hose clamps (28) 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 850 mm (33.5 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 330 mm (13.0 in) and 630 mm (24.8 in) from the front end (boom side) of the hydraulic hoses (23), and (25).

• Fasten the wire bands (16) at a position 490 mm (19.3 in) from the front end (boom side) of the hydraulic hoses (23), and (24).

3-11 EN

3 - ASSEMBLY

9. Install the stud (15) and elbow (20) on the control valve (*2) Pr port.

• Fasten the elbow (20) with the horizontal angle of about 95 °down.

325275D1

10

3697E013

11

BE27C802

12

FD5A46F6

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 (14).

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

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 640 mm (25.2 in) from the front end (hydraulic pump side) of the hydraulic hose (19).

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

3-12 EN

3 - ASSEMBLY

13. Install the elbow (50) on the hydraulic pump (*7).

• Fasten the elbow (50) with the horizontal angle of about 45 ° down.

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

1.

Fasten the elbow (50) with the horizontal angle of about 50 ° up.

Connect the hydraulic pump (*7) and the suction line (*11) with the hydraulic hose (19).

68B609D7

14

3-13 EN

3 - ASSEMBLY

Pilot line installation - proportional control

SMIL15CEX2655FB

1

SMIL15CEX2676FB

2

3-14 EN

3 - ASSEMBLY

3

0D895122

*1. Floor *2. Manifold

*3.

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

0FC9AB24

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)

3-15 EN

3 - ASSEMBLY

3. Install the tee (51) on the manifold (*2) T5 port.

Connect the reducing valve (36) T port and manifold (*2) T5 port with the nylon hose (43–4).

5CDBF4FF

6

625DA844

7

7C6153BA

8

7EA27A15

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 tee (51) on the manifold (*2) P5 port.

Connect the reducing valve (36) P port and manifold (*2) P5 port with the nylon hose (43–3).

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)

3-16 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 nylon hose (43–2).

8BAB2444

10

DE0A3173

11

E5015D53

12

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)

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 nylon hose (43–1).

Fasten the nylon hose (43–1) with three wire bands (46).

3-17 EN

3 - ASSEMBLY

10. Fasten the nylon hose that comes out from the reducing valve (36) with the wire band (46) and mount clamp (53).

Install the two pressure switches (47) on the reducing valve (36).

Fasten the nylon hose with four wire bands (48).

4C56D606

13

SMIL15CEX3030AB

14

11. Fasten the nylon hose with four wire bands (48).

3-18 EN

3 - ASSEMBLY

Harness installation - Proportional control

SMIL15CEX2752FB

1

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

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

Fasten the wire harness (78) with the wire band (79).

• Fasten the wire harness (78) together with the pressure switch harness.

521228DF

2

SMIL15CEX2680AB

3

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

Fasten the wire harness (78) at two locations with two wire bands (79).

3-19 EN

3 - ASSEMBLY

3. Connect the wire harness (78) connector (8-pin) to the harness (*3).

SMIL15CEX2681AB

4

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

SMIL15CEX2682GB

1

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

2. Attach the operation label (switch control) (72) and operation label (proportional control) (73).

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 U Upper main line installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8

EN

SERVICE - Technical Publications & Tools

© 2016 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