Case DV207 Vibratory Roller Service Manual PN 84555711A - PDF DOWNLOAD

DV207 Vibratory Roller

SERVICE MANUAL

Part number 84555711A English April 2012

DV207

3ERVICE -ANUAL Print No. 84555711A

QUICK REFERENCE – CHAPTER GUIDE SECTION 00 – MAINTENANCE GENERAL INSTRUCTIONS 1.

Introduction

2.

Safety precautions

3.

Repair safety precautions

4.

Product identification

5.

Check the tightening of bolted joints

SECTION 00 – MAINTENANCE GENERAL SPECIFICATIONS 6.

Description of the machine

7.

Tooling

SECTION 10 – ENGINE 8.

Removing the engine

9.

Removing the cooler

SECTION 35 – HYDRAULIC SYSTEM 10. Hydraulic system 11. Hydraulics

SECTION 39 – FRAMES 12. Articulated joint 13. Removing the hood

SECTION 41 - STEERING 14. Steering cylinder

SECTION 44 – AXLES AND WHEELS 15. Removing the drum

SECTION 50 – CAB CLIMATE CONTROL 16. Removing the heater/cooling air fans

SECTION 55 – ELECTRICAL SYSTEM 17. Electrical installation 18. Electrical system

SECTION 90 – CAB 19. Cab

INDEX

TABLE OF CONTENTS

Contents SECTION 00 – MAINTENANCE GENERAL INSTRUCTIONS 1.

Introduction ..............................................................................................................................1-1

2.

Safety precautions ...................................................................................................................2-1 2.1.

Safety section ...................................................................................................................................................2-2

2.1.1. Precautionary statements – personal safety signal words................................................................................2-2 2.1.2. Machine safety and information signal words ...................................................................................................2-2 2.1.3. General safety rules ..........................................................................................................................................2-3 2.1.4. General operating safety ..................................................................................................................................2-4 2.2.

Safety sign location overview ...........................................................................................................................2-5

2.2.1. Safety signs ......................................................................................................................................................2-6 2.3.

General maintenance safety ...........................................................................................................................2-10

2.3.1. Fire and explosion prevention .........................................................................................................................2-10 2.3.2. Hazardous chemicals ..................................................................................................................................... 2-11 2.3.3. Battery safety .................................................................................................................................................. 2-11 2.3.4. Air conditioning system ..................................................................................................................................2-12 2.3.5. Transportation safety ......................................................................................................................................2-12 2.3.6. Proper entry and exit ......................................................................................................................................2-12 2.3.7. Operator presence system .............................................................................................................................2-12 2.3.8. Operator protective structure ..........................................................................................................................2-13 2.3.9. Utility safety ....................................................................................................................................................2-13 2.4.

3.

4.

Repair safety precautions .......................................................................................................3-1 3.1.

Safety regulations .............................................................................................................................................3-2

3.2.

Ecological measures & hygiene principles .......................................................................................................3-6

3.3.

Fire measures ...................................................................................................................................................3-7

Product identification ...............................................................................................................4-1 4.1.

5.

Hand signals ...................................................................................................................................................2-14

Summary of applications ..................................................................................................................................4-2

Check the tightening of bolted joints ......................................................................................5-1 5.1.

Check the tightening of bolted joints .................................................................................................................5-2

SECTION 00 – MAINTENANCE GENERAL SPECIFICATIONS 6.

Description of the machine .....................................................................................................6-1 6.1.

Machine construction ........................................................................................................................................6-2

6.2.

Fluid/lubricant specifications .............................................................................................................................6-3

6.2.1. Engine oil ..........................................................................................................................................................6-3 6.2.2. Fuel ...................................................................................................................................................................6-4 6.2.3. Coolant .............................................................................................................................................................6-5 6.2.4. Hydraulic oil .....................................................................................................................................................6-5 6.2.5. Lube grease .....................................................................................................................................................6-5 6.2.6. Washer fluid .....................................................................................................................................................6-5 6.2.7. Gear oil .............................................................................................................................................................6-5 6.3.

Technical data DV207 .......................................................................................................................................6-6

6.4.

Dimensional diagram DV207 ............................................................................................................................6-8

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1

TABLE OF CONTENTS 7.

Tooling ......................................................................................................................................7-1 7.1.

Tooling and equipment ......................................................................................................................................7-2

SECTION 10 – ENGINE 8.

Removing the engine ...............................................................................................................8-1

9.

Removing the cooler ................................................................................................................9-1

SECTION 35 – HYDRAULIC SYSTEM 10. Hydraulic system ...................................................................................................................10-1 10.1.

Hydraulic diagram ...........................................................................................................................................10-3

11. Hydraulics ................................................................................................................................11-1 11.1.

Removing the cooling hydromotor .................................................................................................................. 11-4

11.2.

Removing the gear pump for steering ........................................................................................................... 11-8

11.3.

Removing the tandem pumps for vibration and travel .................................................................................. 11-14

11.3.1. Vibration pump .............................................................................................................................................. 11-14 11.3.2. Travel pump .................................................................................................................................................. 11-16 11.4.

Adjusting vibration frequency ........................................................................................................................ 11-18

11.5.

Adjusting pulse sensors ................................................................................................................................ 11-19

11.6.

Measuring hydraulic circuit safety pressures ............................................................................................... 11-20

SECTION 39 – FRAMES 12. Articulated joint ......................................................................................................................12-1 12.1.

Preparation work .............................................................................................................................................12-4

12.2.

Removing the steering joint ..........................................................................................................................12-10

12.3.

Removing the slewing ring bearing ...............................................................................................................12-15

12.4.

Removing the steering joint bearing .............................................................................................................12-16

12.5.

Installing the steering joint bearing ...............................................................................................................12-19

12.6.

Adjusting the zero position of the steering joint ............................................................................................12-22

13. Removing the hood.................................................................................................................13-1

SECTION 41 - STEERING 14. Steering cylinder .....................................................................................................................14-1 14.1.

Removing hydraulic cylinders for steering and CRAB ....................................................................................14-4

14.2.

Replacing packing material for steering or Crab hydraulic cylinders .............................................................14-5

SECTION 44 – AXLES AND WHEELS 15. Removing the drum ................................................................................................................15-1 15.1.

Removing the vibration hydromotor ..............................................................................................................15-12

15.2.

Removing the travel hydromotor ...................................................................................................................15-14

15.3.

Removing the auxiliary transmission ............................................................................................................15-16

15.4.

Removing the front drum ..............................................................................................................................15-18

15.5.

Replacing the rubber mounting of the drum .................................................................................................15-30

SECTION 50 – CAB CLIMATE CONTROL 16. Removing the heater/cooling air fans ...................................................................................16-1

2

16.1.

Removing the heater ......................................................................................................................................16-4

16.2.

Removing cooling air fans ..............................................................................................................................16-8

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TABLE OF CONTENTS SECTION 55 – ELECTRICAL SYSTEM 17. Electrical installation ..............................................................................................................17-1 17.1.

Fuses ..............................................................................................................................................................17-2

17.2.

Storage battery ...............................................................................................................................................17-4

17.3.

Alternator ........................................................................................................................................................17-5

17.4.

Starter motor ...................................................................................................................................................17-7

17.5.

Layout of wiring elements in the machine.....................................................................................................17-10

18. Electrical system .....................................................................................................................18-1 18.1.

Wiring diagram DV207 ....................................................................................................................................18-3

SECTION 90 – CAB 19. Cab ...........................................................................................................................................19-1 19.1.

Idle and parking brake position sensor ...........................................................................................................19-4

19.2.

Left-hand control panel, reversing horn sensor ..............................................................................................19-4

19.3.

Seat platform ..................................................................................................................................................19-8

19.4.

Power steering servo ....................................................................................................................................19-12

19.5.

Seat switch ...................................................................................................................................................19-16

INDEX

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3

TABLE OF CONTENTS

4

DV 207

SERVICE MANUAL

SECTION 00 – MAINTENANCE GENERAL INSTRUCTIONS 1. Introduction

DV 207

1-1

SECTION 00 – MAINTENANCE – CHAPTER 1 This service manual is divided into several chapters. It includes technical and assembly data, adjustment guidelines and instructions in the use of special tools, jigs and aids.

The primary purpose of this Service Manual is to provide basic information on removal, installation and servicing/ repair of the machine’s main groups.

Machine group identification in this manual corresponds to the Spare Parts Catalog.

Before beginning work, we recommend that you mark any removed parts that will be reinstalled and that you cover all holes in individual hydraulic system parts to prevent hydraulic circuit contamination.

When installing individual parts in the machine, tighten individual bolts or nuts as indicated in the torque tables (appendix) unless otherwise indicated in the text.

ALWAYS observe the safety instructions and precautions indicated in Chapter 2.

The manufacturer is continually improving the products based on operational experience and the latest knowledge.

Consequently, the manufacturer reserves the right to make changes to the illustrations, descriptions, procedures or design patterns given in this manual as developments are made.

1-2

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SERVICE MANUAL

FRONT

RIGHT

LEFT

REAR 400101en

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1-3

SECTION 00 – MAINTENANCE – CHAPTER 1 Notes

1-4

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SERVICE MANUAL

SECTION 00 – MAINTENANCE 2. Safety precautions

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2-1

SECTION 00 – MAINTENANCE – CHAPTER 2 2.1. Safety section Your safety and that of people around you depends on you. It is essential that you understand this manual to ensure the correct operation, inspection and maintenance of this machine.

Read this manual carefully and check that you fully understand: -

The symbols on the controls and the safety signs used in this manual and on the machine.

-

The speed, stability, braking and steering characteristics of the machine. If you are in any doubt, consult your dealer.

The safety messages in this manual concern situations which may arise during normal machine operation and servicing. These safety messages also indicate the various ways of coping with these situations.

2.1.1. Precautionary statements – personal safety signal words

This is the safety alert symbol. It is used to alert you to potential personal injury hazards.

Obey all safety messages that follow this symbol to avoid possible injury or death.

Throughout this manual and on the machine safety signs, you will find the signal words DANGER, WARNING and CAUTION followed by specific instructions. These precautions are intended for the personal safety of you and those working with you. Please take the time to read them.

DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. The color associated with DANGER is RED.

WARNING WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. The color associated with WARNING is ORANGE.

CAUTION CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. The color associated with CAUTION is YELLOW. FAILURE TO FOLLOW DANGER, WARNING AND CAUTION INSTRUCTIONS COULD RESULT IN DEATH OR SERIOUS INJURY.

2.1.2. Machine safety and information signal words NOTICE: NOTICE indicates a situation that could result in machine or property damage if not avoided. The color associated with NOTICE is BLUE. Throughout this manual, you will find the signal word NOTICE followed by special instructions to prevent machine or property damage. The word NOTICE is used to address practices not related to personal safety.

NOTE: NOTE indicates additional information that clarifies steps, procedures or other information in this manual.

Throughout this manual, you will find the word NOTE followed by additional information about a step, procedure or other information in the manual. The word NOTE is not intended to address personal safety or property damage.

2-2

DV 207

SERVICE MANUAL 2.1.3. General safety rules

d. Replace all parts that have damage or wear.

• Never operate the machine under the influence of alcohol, drugs or while otherwise impaired.

• Never permit anyone other than the machine operator to ride on the machine.

• A person or pet within the operating area of a machine can be struck or crushed by the machine or its equipment. DO NOT allow anyone to enter the work area.

• Any person who operates the machine or performs machine maintenance or repairs must be familiar with the guidelines given in this Operator’s Manual.

e. Replace belts that have cuts that can make the belt weak. f. Check that bolts on the seat bracket or mounting are tight. g. If the belt is attached to the seat, make sure the seat or seat brackets are mounted securely. h. Keep seat belts clean and dry. i. Clean belts with soap solution and warm water only. j. Do not use bleach or dye on the belts because this can make the belts weak.

• Keep clear of moving parts. Loose clothing, jewelry, watches, long hair and other loose or hanging items can become entangled in moving parts.

• Always use personal protective equipment (PPE), such as work clothing, safety boots, hard hat and hearing protection.

• Make sure all guards and shields are in good condition and properly installed before operating the machine. Never operate the machine with the shields or guards removed.

• Make sure all components are in good condition and tighten all connections before starting the engine or pressurizing the system.

• Dirty or slippery steps, ladders, handholds, walkways and platforms can cause falls. Make sure these surfaces remain clean and clear of debris.

• Operate machine controls only when seated in the operator seat.

• Before starting the machine, be sure that the drive controls are in their neutral position.

• DO NOT attempt to remove material from any part of the machine while it is being operated or components are in motion.

• Never smoke or handle open flames when checking or pumping fuels, refilling oils, lubricating the machine or inspecting or pressurizing the accumulator.

• Seat belt inspection and maintenance: a. Keep seat belts in good condition. b. Keep the belts away from sharp edges and items that could cause damage. c. Periodically check belts, buckles, retractors, tethers, slack take-up system and mounting bolts for damage.

CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.

Battery posts, terminals and related accessories contain lead and lead compounds. Wash your hands after handling.

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2-3

SECTION 00 – MAINTENANCE – CHAPTER 2 2.1.4. General operating safety Before starting work, the operator must do the following: • Be familiar with the work site environment, i.e. with the slopes, utility line system, as well as with necessary types of work site protections.

• Indicate each machine start-up with an acoustic or light signal and allow a few moments for personnel to leave the work area before turning on the machine engine.

• Confirm brake and steering functionality before operating the machine.

• Always make sure the work area is clear of tools, parts, other persons and pets before you start operating the machine.

• Always keep windows, mirrors, all lighting and the Slow Moving Vehicle (SMV) emblem clean to provide the best possible visibility while operating the machine.

• Never operate the machine in enclosed spaces as harmful exhaust gases may build up.

• DO NOT operate the machine during an electrical storm.

-

-

If lightning should strike during operation, remain in the cab. Do not leave the cab or operator’s platform. Do not make contact with the ground or objects outside the machine.

If you are on the ground during an electrical storm, stay away from machinery and equipment. Seek shelter in a permanent, protected structure.

• DO NOT operate the machine when within hazardous reach of other machines or transportation means aside from those that operate in mutual concert with the machine.

• DO NOT operate the machine at places impossible to see from the operator platform and where hazard to people or property could occur unless work safety has been secured through some other way, such as via signaling by duly instructed personnel.

• DO NOT operate the machine under reduced visibility or at night, unless the machine’s work area and the work site are illuminated sufficiently.

• Pay attention to overhead power lines and hanging obstacles. High voltage lines may require significant clearance for safety. If the machine comes into contact with high voltage, observe the following principles: -

do not attempt to leave the operator platform while in the hazardous zone

-

warn others to keep off and not touch the machine

-

try to drive the machine out of the hazardous zone

• When parking the machine on a road, always take into consideration the effect the weight of the machine will have on the road.

• Exposure to loud noises could cause hearing damage. Always wear hearing protection when operating noisy equipment or when working in a noisy environment.

• Before leaving the machine: a. Park the machine on a firm, level surface. b. Put the drive controls in their neutral position. c. Turn off the engine and remove the key.

• Start the engine from the operator seat only.

• DO NOT roll and compact at slopes of such angles where there is a risk of soil breaking off (dropping) under the machine or a risk of loss of grip followed by uncontrolled slip.

• Depending on the bearing capacity of the subsoil, DO NOT roll and compact at such a distance from the edge of the slope or trench that there is a risk of landslide or the shoulder breaking off (dropping) together with the machine.

• DO NOT roll and compact with vibration at such a distance from walls, cuts or slopes that would cause them to slip (slide) and cover the machine.

• DO NOT compact with vibration at such a distance from buildings or facilities and equipment that there is a risk of them being damaged due to vibration transfer impact.

2-4

DV 207

SERVICE MANUAL 2.2. Safety sign location overview The following safety signs have been placed on your machine in the areas indicated. They are intended for the personal safety of you and those working with you. Please take this manual and walk around your machine to note the content and location of these safety signs. Review these safety signs and the operating instructions detailed in this manual with your machine operators. Keep the safety signs legible. If they are not, obtain replacements from an authorized dealer. The safety sign replacement part numbers are listed with each safety sign.

#

"

%

'

$

&

"

&

%

'

#

$

%7 $/)

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2-5

SECTION 00 – MAINTENANCE – CHAPTER 2 2.2.1. Safety signs NOTICE Clean the safety signs and keep them legible – do not use solvent, gasoline or other harsh chemicals to clean the safety signs.

Replace all worn, damaged or missing safety signs.

If a safety sign is on a part that is replaced, make sure the new part has the safety sign.

1.

Runover hazard!

Maintain a safe distance from the machine. Failure to comply will result in death or serious injury. (Symbol located at the back)

DANGER RUNOVER HAZARD

Keep clear of machine.

3461

Part no.: ND148560

ND 148560

3461bz

Quantity: 1 2.

Explosion hazard!

Read the procedure in the Operator’s Manual before jump starting or servicing to avoid injury.

Failure to comply will result in death or serious injury. (Symbol located on the inner side of the battery door at the rear of the machine)

DANGER EXPLOSION HAZARD Read procedure in Operator‘ s Manual before jump start or service to avoid injury.

CA 412471A1

2880

ND 106 581

2880bz

Part no.: ND106581 Quantity: 1 3. Starting in gear can cause death!

Starting in gear could cause death. Start the engine from the operator seat only with the transmission control(s) in neutral. Failure to comply will result in death or serious injury. (Symbol located on the hood)

DANGER Starting in gear can cause death. Start engine only from operator seat with transmission control (s) in NEUTRAL 2878

CA 321-7040

Part no.: ND106579 Quantity: 1

ND 106 579

2878bz

4.

Hot surface hazard!

Maintain a safe distance from the hot part of the machine. Failure to comply could result in death or serious injury. (Symbol located above the exhaust)

WARNING

Part no.: ND106591 HOT SURFACE HAZARD Keep clear 2890

CA 283608A1

Quantity: 1

ND 106 591

2890bz

5.

Hot liquid under pressure hazard!

3408

Do NOT open the expansion tank cap until the liquid cools down below 50°C (122°F). Failure to comply could result in death or serious injury.

(Symbol located on the righthand side of the hood above the door)

ND 146 955

3408bz

Part no.: ND146955 Quantity: 1

6.

Entanglement hazard!

W WARNING ENTANGLEMENT HAZARD Keep clear or stop engine before servicing.

2913

ND 109 916

2913bz

Maintain a safe distance from the rotating cooling fan, pulley and belt. Keep clear or stop engine before servicing. Failure to comply could result in death or serious injury. (Symbol located on the right side of the hood and on the cooler) Part no.: ND109916 Quantity: 2

2-6

DV 207

SERVICE MANUAL 7.

Adjust when stationary!

WARNING

Remove key and read Service Manual before servicing machine.

2891

ND 106 592

2891bz

8.

Welding hazard!

WARNING

Read Operator's Manual before welding on machine.

2892

Do NOT perform any adjustments or maintenance while the engine is running. Stop the engine, remove the ignition key and read the Service Manual before servicing the machine.

Failure to comply could result in death or serious injury. (Symbol located on the left-hand side) Part no.: ND106592 Quantity: 1 Read Operator’s Manual before welding on the machine. Disconnect the alternator before welding on the machine. Failure to comply could result in death or serious injury. (Symbol located on the dashboard) Part no.: ND106593 Quantity: 1

ND 106 593

CA Cv002

2892bz

9.

Danger area WARNING

Maintain a safe distance from the machine. Failure to comply could result in death or serious injury. (Symbols located on both sides of the machine) Part no.: ND106586 Quantity: 2

HAZARDOUS AREA Keep clear 2885

ND 106 586

2885bz

10. Clamping hazard WARNING

Part no.: ND106588

CRUSH HAZARD Keep Clear 2887

Maintain a safe distance from the machine. Risk of being clamped between the front and rear frame of the machine. Failure to comply could result in death or serious injury. (Symbols located on the left and right near steering joint) Quantity: 4

ND 106 588

CA 283606A1

2887bz

11. Read Operator’s Manual!

WARNING

Read Operator’ s Manual.

Fasten seat belt.

No riders.

Keep others away.

2883

CA 382622A1

ND 106584

2883bz

Before starting the machine, thoroughly read the safety measures and instructions for controlling the machine and its actuators in the manuals supplied with the machine. Fasten the seat belt.

Do not carry passengers or riders. Keep others away. Failure to comply could result in death or serious injury. (Symbol located on the dashboard) Part no.: ND106584 Quantity: 1

12. Crush hazard!

WARNING

Avoid crushing. Do not jump if machine tips. Use the seat belt. Failure to comply could result in death or serious injury. (Symbol located on the dashboard Part no.: ND148014 Quantity: 1

AVOID CRUSHING DO NOT JUMP IF MACHINE TIPS

USE SEAT BELT 3447

ND 109 913

3447bz

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2-7

SECTION 00 – MAINTENANCE – CHAPTER 2 13. Crush hazard!

Engage the hood lock before servicing the machine. Failure to comply could result in death or serious injury. (Symbol located on the left hand side)

WARNING

WARNING CRUSH

Part No.: ND147576

Engage hood lock before service.

3431

Quantity: 1 ND-147 576

3431bz

14. Crush hazard!

Secure the steering joint (lock link) when loading and transporting the machine on a vehicle.

Failure to comply could result in death or serious injury. (Symbol located to the left on the rear frame near the joint)

WARNING

CRUSH HAZARD Engage lock link before service or transport.

Part No.: 84595622 Quantity: 1

3570

3570bz

15. Hood locking

Lock the hood. (Symbol located on the left side of the machine) Part no.: ND140504 Quantity: 1

2939

3326bz

16. Crush hazard!

Make sure that no one is within the danger area surrounding the edge cutter. Failure to comply could result in death or serious injury. (Symbol located on right-hand side of the machine (option))

WARNING

CRUSH HAZARD

Part No.: ND147578

Keep clear!

3433

Quantity: 1

ND 147 578

3433bz

17. Lifting diagram

Use rigging of sufficient loading capacity to lift the Machine. Secure the Machine’s joint before lifting. (Symbol located on the left side of the machine)

8400 kg (18 600 lb)

Lmin = 5m 2x min 2100 kg Lmin = 5 m

(2x min 4650 lb)

2x min 2100 kg (2x min 4650lb)

Part no.: ND140503 Quantity: 1 3325

3325bz

18. Lifting lugs

Lift the machine using these lugs. (Symbol located on both sides of the machine) Part no.: ND081460 2153bz

19. Sling points

Quantity: 4 The machine is to be rigged in these points.

(Symbols located on both sides of the machine) Part no.: ND119495

3048bz

2-8

Quantity: 4

DV 207

SERVICE MANUAL 20. Machine’s max height

Caution when passing locations with height limit.

(Symbol located on the left beneath the cabin, on the Machine frame)

10ft/3,05m

Part no.: ND128599

3207

Quantity: 1

21. Jacking point

Place to install hand jack or fixed support of the machine. (Symbol located on both sides of the machine) Part No.: ND128663

3208bz

Quantity: 4 22. Read Operator’s Manual

The Operation Manual stowage box. (Symbol located on the box at the rear of the seat) Part no.: ND081612 2428bz

Quantity: 1

23. Coolant

Coolant is hazardous to health. Read the Operator’s Manual before filling up or changing coolant. (Symbol located on the coolant tank) 3323bz

Part no.: ND140501 Quantity: 1

24. Hood lifting

Pump to lift the hood. (Symbol located on the inner side of the disconnector door) Part no.: ND148109 Quantity: 1 3445

3445

25. Hearing protection required

Wear hearing protection with the machine if it does not have a cab. (Symbol located on the dashboard) 2408bz

Part no.: ND081592 Quantity: 1

26. No washing

Cover electrical devices when washing the machine. (Symbol located on the dashboard) Part no.: ND081530 Quantity: 1

2225bz

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2-9

SECTION 00 – MAINTENANCE – CHAPTER 2 2.3. General maintenance safety • Before you begin machine servicing, attach a “DO NOT OPERATE” warning tag to the machine in an area that will be visible.

specified in the Spare Parts Catalog.

• Jack or lift the machine only at the jacking or lifting points indicated in this manual.

• Stop the engine, remove the key and relieve the pressure before connecting or disconnecting fluid lines.

• Stop the engine and remove the key before disconnecting or connecting electrical connections.

• When welding, follow the instructions in the manual. Always disconnect the battery before welding on the machine. Always wash your hands after handling battery components.

• Service on the machine must only be performed by a professionally trained person using appropriate tools and in compliance with the safety instructions located in the manuals shipped with the machine.

• Do not attempt to clean, lubricate, clear obstructions or make adjustments to the machine while it is in motion or while the engine is running.

• Keep the area used for servicing the machine clean and dry. Clean up spilled fluids.

• Only service the machine on a firm level surface, secured against accidental movement (wheel chocks), with the engine OFF, the key removed, the battery disconnected and the drive controls in their neutral position.

• Improper removal of coolant caps could result in scalding. The cooling system operates under pressure. Hot coolant can spray out if a cap is removed while the system is hot. Allow the system to cool before removing the cap. When removing a cap, turn it slowly to allow pressure to escape before completely removing the cap.

• Engine, transmission, exhaust components and hydraulic lines may become hot during operation.

Take care when servicing such components. Allow surfaces to cool before handling or disconnecting hot components. Wear personal protective equipment, such as hard hat, safety glasses or goggles, heavy gloves, hearing protection and protective clothing.

• The body must be protected with proper gloves and clothing.

• Close all access doors and install all panels, guards and shields after servicing the machine.

• Replace damaged or worn tubes, hoses, electrical wiring, etc.

• Only replace parts with new, genuine parts

2-10

• When the machine is taken out of service because it is damaged beyond repair or has reached the end of its service life, removal, scrapping and/or recycling of components, fluids, etc. must only be performed by a qualified technician using service instructions and in compliance with local laws and regulations.

• Hydraulic oil or diesel fuel leaking under pressure can penetrate the skin, causing serious injury or infection.

-

DO NOT use your hand to check for leaks. Use a piece of cardboard or paper.

-

If hydraulic oil or diesel fuel penetrates the skin, seek medical attention immediately.

-

If hydraulic oil or diesel fuel comes into contact with the skin, wash the affected area immediately.

-

Continuous, prolonged contact with hydraulic oil may cause skin cancer. Avoid prolonged contact and wash the skin promptly with soap and water.

2.3.1. Fire and explosion prevention • Always have a fire extinguisher on or near the machine.

• Make sure the fire extinguisher is maintained and serviced according to the manufacturer's instructions.

• Do not smoke or use an open flame when at work.

• Fuel or oil leaks or spills on hot surfaces or electrical components could cause a fire.

• Trash, debris, bird nests or flammable material can ignite on hot surfaces.

• At least once each day and at the end of the day, remove all trash and debris from the machine especially around hot components such as engine, transmission, exhaust, battery, etc. More frequent cleaning of the machine may be necessary depending on the operating environment and conditions.

• At least once each day, remove debris accumulation around moving components such as bearings,

DV 207

SERVICE MANUAL pulleys, belts, gears, fan, etc. More frequent cleaning of the machine may be necessary depending on the operating environment and conditions.

• Inspect the electrical system for loose connections or frayed insulation. Repair or replace loose or damaged parts.

2.3.3. Battery safety For specific information on the machine’s battery and electrical system, refer to electrical system sections in this manual.  Always wear eye protection when working with batteries.

• Do not store oily rags or other flammable material on the machine.

• Do not create sparks or have an open flame near a battery.

• Do not weld or flame cut any items that contain flammable material. Clean items thoroughly with non-flammable solvent before welding or flame cutting.

• Ventilate when charging or using in an enclosed area.

• Do not expose the machine to flames or explosives.

• Promptly investigate any unusual smells or odors that may occur during operation of the machine.

2.3.2. Hazardous chemicals • If you are exposed to or come in contact with hazardous chemicals, you can be seriously injured.

The fluids, lubricants, paints, adhesives, coolant, etc. required for the function of your machine can be hazardous. They may be attractive and harmful to domestic animals as well as humans.

• Material Safety Data Sheets (MSDS) provide information about the chemical substances contained in a product, safe handling and storage procedures, first-aid measures and procedures to be taken in the event of a spill or accidental release.

MSDS are available from your dealer.

• Before servicing your machine, check the MSDS for each lubricant, fluid, etc. used in this machine.

This information indicates the associated risks and will help you service the machine safely. Follow the information in the MSDS, on manufacturer containers and in this manual when servicing the machine.

• Dispose of all fluids, filters and containers in an environmentally safe manner in accordance with local laws and regulations. Check with local environmental and recycling centers or your dealer for correct disposal information.

• Store fluids and filters in accordance with local laws and regulations. Use only appropriate containers for the storage of chemicals or petrochemical substances.

• Keep out of reach of children and other unauthorized persons.

• Additional precautions are required for applied chemicals. Obtain complete information from the manufacturer or distributor of the chemicals before using them.

• Never mix diesel with gasoline or alcohol. These mixtures may cause an explosion.

• Disconnect the negative (-) terminal first and reconnect the negative (-) terminal last.

• When welding on the machine, disconnect both terminals of the battery.

• Do not weld, grind or smoke near battery.

• When using auxiliary batteries or connecting booster cables to start the engine, use the procedure shown in Operator’s Manual chapter “17. Electrical installation”.

• Follow manufacturerʼs instructions when storing and handling batteries.

• Battery posts, terminals and related accessories contain lead and lead compounds. Wash your hands after handling. Lead is a toxic substance.

This is a California Proposition 65 Warning.

• Battery acid causes burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes and clothing.

-

Antidote (external): flush with water.

-

Antidote (eyes): flush with water for 15 minutes and seek medical attention immediately.

-

Antidote (internal): drink large quantities of water or milk. Do not induce vomiting. Seek medical attention immediately.

• Keep out of reach of children and other unauthorized persons.

• Use rubber gloves and safety glasses when handling the batteries.

• Protect your skin and clothing against any stain caused by electrolyte or lead particles..

• If electrolyte comes in contact with the eyes, immediately flush the eyes with large amounts of water for several minutes. Get prompt medical attention.

• If skin or clothing is stained with electrolyte, remove the contaminated clothing and flush immediately with large amounts of soapy water or a baking soda/water solution. Get prompt medical attention.

• If electrolyte is ingested, give as much milk, calcined magnesia dissolved in water or plain water as possible and get prompt medical attention.

• Do not smoke, weld, grind or use an open flame near hazardous chemicals.

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2-11

SECTION 00 – MAINTENANCE – CHAPTER 2 • NEVER top up cells with distilled water unless work with the machine or recharging outside the machine will follow. Increased self-discharging of the battery would occur.

2.3.6. Proper entry and exit

• NEVER replenish the acid (H2SO4)!

• Do not use the steering wheel or other controls or accessories as handholds when entering or exiting the machine cab or operator platform.

• Do NOT turn the batteries over. Electrolyte could pour out from the degassing holes of the battery.

• When acid (electrolyte) is spilled, flush the hit spot with water and neutralize with lime.

• When the batteries are recharged, hydrogen is released and when mixed with air forms an explosive, flammable mixture. Do NOT handle near an open flame or smoke nearby.

• See “Safety Precautions for work on wiring”

2.3.4. Air conditioning system • The air conditioning system is under high pressure.

Do not disconnect any lines. The release of high pressure can cause serious injury.

• Proper entry or exit from the cab is the same on both sides.

• Face the machine when mounting and dismounting.

• Maintain a three-point contact with steps, ladders and handholds.

• Mount and dismount the machine only at designated locations that have handholds, steps or ladders.

• Do not jump off the machine.

• Never mount or dismount from a moving machine.

• Make sure steps, ladders and platforms remain clean and clear of debris and foreign substances.

Injury may result from slippery surfaces.

• The air conditioning system contains gases that are harmful to the environment when released into the atmosphere. Do not attempt to service or repair the system.

• Service, repair or recharging must be performed only by a trained service technician.

• Always wear safety protection when working around liquid refrigerant. Refrigerant can cause serious injury to the eyes and skin.

2.3.5. Transportation safety For specific information on towing, loading, lifting or transporting the machine, refer to the operating instructions section in this manual.

2.3.7. Operator presence system

• Incorrect towing procedures can cause accidents.

When towing a disabled machine, follow the procedure in this manual.

• Your machine is equipped with an operator presence system to prevent the use of some features if the operator is not in the operator seat.

Driving on public roads • Comply with local laws and regulations.

• The operator presence system should never be disconnected or bypassed.

• Use appropriate lighting to comply with local regulations.

• If there is a fault in the system, the system must be repaired immediately.

• Make sure the Slow Moving Vehicle (SMV) emblem is visible.

• Slow down and signal before turning.

• Pull over to allow faster traffic to pass.

Transporting the machine • When transporting machine on a transport trailer, make sure it is properly secured. Be sure the SMV emblem on the machine is covered while it is being transported on a trailer.

• Be aware of overhead structures or power lines and make sure the machine can pass safely under.

• Travel speed should be such that complete control and machine stability is maintained as all times.

2-12

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SERVICE MANUAL 2.3.8. Operator protective structure

2.3.9. Utility safety

The protective structure is a special safety component of your machine and each machine is equipped with one of the following operator protective structures:

ALWAYS have all local utility companies mark the location of their lines. Before beginning any machine operation, it is your responsibility to be aware of all utility lines buried and overhead in the area of your project and to avoid them.

-

Rollover Protective Structure (ROPS)

-

Falling Object Protective Structure (FOPS)

-

Cab with ROPS

A ROPS may be a cab frame or a two-posted or four-posted structure used for the protection of the operator to minimize the possibility of serious injury.

The mounting structure and fasteners forming the mounting connection with the machine are part of the ROPS. • Seat belts are part of your protective system and must be worn at all times. The operator must be held to the seat inside the frame in order for the protective system to work.

• DO NOT attach any device to the protective structure for pulling purposes.

• DO NOT weld, drill holes, attempt to straighten or repair the protective structure. Modification in any way can reduce the structural integrity of the structure, which could cause death or serious injury in the event of a fire, tip, rollover, collision or accident.

The protective structure and interconnecting components are a certified system. Any damage, fire, corrosion or modification will weaken the structure and reduce your protection. If this occurs, the protective structure MUST be replaced so that it will provide the same protection as a new protective structure.

Contact an authorized dealer for protective structure inspection and replacement.

After an accident, fire, tip or rollover, the following MUST be preformed by a qualified technician before returning the machine to field or work site operation: -

The protective structure MUST be replaced.

-

The mounting or suspension for the protective structure, operator seat and suspension, seat belts and mounting components and wiring within the operatorʼs protective system MUST be carefully inspected for damage.

-

All damaged parts MUST be replaced.

-

DO NOT WELD, DRILL HOLES, ATTEMPT TO STRAIGHTEN OR REPAIR THE PROTECTIVE STRUCTURE. MODIFICATION IN ANY WAY CAN REDUCE THE STRUCTURAL INTEGRITY OF THE STRUCTURE, WHICH COULD CAUSE DEATH OR SERIOUS INJURY IN THE EVENT OF FIRE, TIP, ROLLOVER, COLLISION OR ACCIDENT.

DV 207

Check with local authorities for laws, regulations and/ or strict penalties requiring you to locate and avoid existing utilities.

In the U.S.A. and Canada, call one of many “One Call System Directory” services. If you do not know the local number, call the national number (U.S.A. and Canada only): 1-888-258-0808.

CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU PERFORM ANY MACHINE OPERATION Know the utility color code (U.S.A. and Canada): Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red Gas, oil or gasoline. . . . . . . . . . . . . . . . . . . . . . . . Yellow Communication, telephone, television . . . . . . Orange Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blue Sewer . . . . . . . . . . . . . . . . . . . . . . . . . . . . Green/Brown Proposed excavation . . . . . . . . . . . . . . . . . . . . . . . White Surveying . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . Pink Reclaimed water and slurry . . . .. . . . . . . . . . . . . Purple After locating any buried utility lines, carefully dig a hole by hand and/or automatic vacuum equipment to the utility line to verify the location and depth of the line.

The operator must promptly communicate any damage to the utility lines to their owner and at the same time take measures to prevent unauthorized persons from accessing the hazardous area.

2-13

SECTION 00 – MAINTENANCE – CHAPTER 2 2.4. Hand signals When operating the machine, never attempt to carry out tasks calling for fine control or work in areas where visibility is poor or impaired without seeking the assistance of a signalman. Make perfectly sure that you and the signalman understand the signals to be used.

START THE ENGINE

MOVE AWAY FROM ME Move hands forward and rearward (palms out).

STOP THE ENGINE

GO THIS FAR

COME TO ME

ALL STOP AND HOLD

Move hands forward and rearward (palms in).

2-14

DV 207

SERVICE MANUAL STOP

TURN MACHINE LEFT

Move one hand back and forth.

To stop movement, stop moving your hand and make a fist.

EMERGENCY STOP

TURN MACHINE RIGHT

Move both hands rapidly back and forth.

To stop movement, stop moving your hand and make a fist.

DV 207

2-15

SECTION 00 – MAINTENANCE – CHAPTER 2 Notes

2-16

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SERVICE MANUAL

SECTION 00 – MAINTENANCE 3. Repair safety precautions

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3-1

SECTION 00 – MAINTENANCE – CHAPTER 3 3.1. Safety regulations The following safety regulations must be observed by anyone who repairs the machine!

•

Only a skilled, competent, trained and experienced service technician and/or dealer or Service Center of Case Company may repair this machine.

•

ALWAYS use our Service Manual during repair work. Special instructions concerning installation work are given in individual chapters.

•

Before putting the machine into operation, read Operator’s Manual thoroughly to familiarize yourself with the machine controls and make sure you understand all the equipment of your machine before putting the machine into operation.

•

Do NOT use the machine unless you fully understand all the controls and control elements and until your know exactly how the machine operates.

•

Familiarize yourself with the site where you will be working.

•

NEVER convert or adapt the machine because doing so could impair machine safety.

•

Use only genuine parts and accessories designed specifically for this machine.

•

Mounting or using parts that have not been supplied or authorized by the machine manufacturer could negatively impact operating characteristics and safe operation of the machine.

Safety precautions during machine repair or inspection •

Wear protective clothing and shoes.

•

Use protective gloves when handling oil, fuel and coolant.

•

Protect your eyes with safety glasses or a shield when handling the battery.

•

Park the machine on a flat and paved surface before beginning any machine repair work. Secure the machine so it does not to move unexpectedly.

•

Before starting any work, remove the key, disconnect the battery and allow the hot parts to cool down.

•

Attach a “DO NOT OPERATE” sign to the steering wheel and keep it there until repair work is complete.

•

Wash the entire machine properly. If using steam, do not expose electric components or insulation material to the direct steam flow or cover them first.

•

Use caution if using detergents. Do NOT use gasoline or other flammable materials for cleaning purposes!

•

Observe absolute cleanliness of all parts during removal, installation and service repair work. Protect removed parts against any dirt.

•

Clean the surface of removed parts and provide for an adequate dust-free environment along with the storage area required.

•

Clean and dry the parts; then apply corrosion protection oil instantly – NEVER install corroded parts!

•

Tools, hoists, protective devices, supports or other auxiliaries must be in an operable (available) state and in good order.

•

Use hoists and rigging (cables, chains) that are intact and have sufficient load capacity.

•

Provide for adequate air supply when starting in an enclosed area.

•

Before running the machine, make sure no persons are present on the machine or within its hazard zone. Use an acoustic signal to warn that the machine is started. Always do this when starting the machine and after each break before setting the machine in motion. When the acoustic signal sounds, any persons present on the machine or within its hazard zone must leave the machine and the zone. In addition to acoustic and light signals, hand signals must be used as described in chapter “2.4. Hand signals”.

•

NEVER adjust the Machine while it is in motion.

•

If performing emergency work on a running engine (any adjustments), avoid making any contact with hot or rotating parts of the machine. Any work performed while the engine is running (e.g. adjustments) must be done with the presence of another person, who has immediate access to the emergency shutoff switch and maintains continuous communication with the person making the adjustment so engine can be turned OFF instantly if required.

•

Use only the specified types of engine oil, transmission fluid, hydraulic oil and coolant.

3-2

DV 207

SERVICE MANUAL Safety precautions during work on hydraulic circuits •

Check that hydraulic circuits have been depressurized before removing them. Hydraulic oil that leaks under pressure could cause serious skin injury.

•

Mark parts, hoses and pipes before removing them.

•

Do NOT operate hydroelectric generators or hydromotors with no oil.

•

There is a scalding hazard when handling hot oil.

•

Do NOT heat oil over 160°C (320°F) – oil or its vapors could flame up.

•

Use lint-free cloth when wiping and cleaning hydraulic parts.

•

Use hydraulic oil – not lube grease – as lubricating agent during parts installation work.

•

Thoroughly clean the bolting before installation work; flush and blow out the hoses and pipes with air.

•

It is important to ALWAYS use new gaskets.

•

After hydraulic set replacement, flush the hydraulic circuit and clean the hydraulic tank.

•

Replace the oil filter element.

•

Fill the hydraulic circuit with clean oil of the specified viscosity – only with the engine switched off!

•

Wipe up any spilled oil.

•

Confirm that connections are tight with no oil leaks before pressurizing the system.

•

Upon completion of all of the work, check all connections.

•

Do NOT adjust the relief valves.

•

Reinstall all protective elements after the work is completed.

Check the following once the machine is in operation •

Oil level in the hydraulic tank.

•

Check the boost pressure of hydroelectric generators when these are replaced and check relief valve pressure.

•

Always measure at 40°C (104°F).

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3-3

SECTION 00 – MAINTENANCE – CHAPTER 3 Safety precautions for work on fuel system Mixtures of gasoline and diesel (winter fuel) are as flammable as gasoline.

•

Do NOT fill up the tank in an enclosed area.

•

Wipe up any spilled fuel.

•

NEVER use an open flame or smoke when working on the fuel system! Fire hazard!

Safety precautions for work on wiring •

Disconnect the battery when repairing the charging circuit to prevent short circuiting.

•

Before removal work, first disconnect the cable from the negative pole (-) and then from the positive pole (+).

•

Do NOT disconnect batteries while the engine is running!

•

Connect the battery with “negative” pole to the frame, and the “positive” pole to the alternator outlet “B+”.

Reversed connection could destroy the entire semiconductor device.

•

Remove the connection at the machine battery before removing the auxiliary external power supply.

•

Do NOT idle the engine with the alternator disconnected from the “B+” terminal and the “D+” terminal connected.

•

NEVER check for the presence of voltage in a conductor by sparking against the machine frame.

•

Do NOT carry out any operations during which sparking will occur.

•

Use rubber gloves and safety glasses when handling the batteries.

•

Protect your skin and clothing against any stain caused by electrolyte or lead particles.

•

If electrolyte comes in contact with the eyes, immediately flush the eyes with large amounts of water for several minutes. Get prompt medical attention.

•

If skin or clothing is stained with electrolyte, remove the contaminated clothing and flush immediately with large amounts of soapy water or a baking soda/water solution. Get prompt medical attention.

•

If electrolyte is ingested, give as much milk, calcined magnesia dissolved in water or plain water as possible and get prompt medical attention.

•

NEVER top up cells with distilled water unless work with the machine or recharging outside the machine will follow. Increased self-discharging of the battery would occur.

•

NEVER replenish the acid (H2SO4)!

•

Do NOT turn the batteries over. Electrolyte could pour out from the degassing holes of the battery.

•

When acid (electrolyte) is spilled, flush the hit spot with water and neutralize with lime.

•

When the batteries are recharged, hydrogen is released and when mixed with air forms an explosive, flammable mixture. Do NOT handle near an open flame or smoke in the vicinity.

3-4

DV 207

SERVICE MANUAL Welding work on the machine Before performing any electric arc welding work on the machine, disconnect all elements containing semiconductors from the wiring: •

Engine alternator

•

Engine hour meter

•

All electronic elements on the machine

•

Ground the power supply and the machine being repaired

•

Secure the power supply against any moisture

•

Position the ground terminal in close proximity to a weld joint

•

Insulate the electrical current crossing point or use non-conducting rigging (hemp cable) when welding the parts or when the machine is in its suspended position This is because the electrical current could potentially penetrate the lifting equipment.

Gaskets •

Use new gaskets during any and all installation work.

•

Gasket sets are available as spare parts.

Tightening instructions •

Use torque wrenches to ensure the element is tightened to the correct torque.

•

Tighten reused attachment bolts and nuts as indicated in the relevant table (refer to chapter “5.1. Check the tightening of bolted joints”).

•

Bolt quality identification is shown on the bolt head.

•

Tightening torques are stated in relevant chapters.

•

Threaded joints of hydraulic circuits must be tightened as indicated in the tables.

•

The indicated tightening torques apply to non-greased bolt threads.

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3-5

SECTION 00 – MAINTENANCE – CHAPTER 3 3.2. Ecological measures & hygiene principles When repairing the machine, follow general principles of health protection and environmental protection along with the laws, public notices and regulations that are related to these issues and are in force within the territory where the machine is used.

Hygiene principles •

Oil products, coolant, battery fluid and painting materials (incl. thinners) are materials that are hazardous to health and could cause serious harm if they come in contact with body organs.

•

Consequently, when using with these products, pay strict attention to the instructions in the product safety and hygiene manuals and wear personal protective equipment.

•

Workers using with these products during machine repair are obligated to follow general principles of health protection and abide by the safety and hygiene guidelines of the product manufacturers.

Please adhere to the following in particular: -

Protect the eyes and skin when handling batteries

-

Protect the skin when handling oil products, painting materials and coolants

-

Wash your hands properly upon completion of work and before eating; treat your hands with appropriate skin repair cream

-

When handling the cooling system, follow the instructions given in the manuals supplied with the machine

•

Always store oil products, coolant, battery fluid, and painting systems (incl. organic thinners, detergents and preventives) in their genuine, properly-identified packages. Do NOT store these materials in unidentified bottles or other vessels due to the hazard of accidental confusion. The potential of being confused for consumables or drinks is particularly hazardous.

•

If skin, mucosa or eyes are accidentally stained or vapors are inhaled, apply first-aid principles immediately. If such products are accidentally ingested, get prompt medical attention.

•

Refer to the Material Safety Data Sheet (MSDS) for treatment information if substance is contacted, inhaled or swallowed.

Ecological measures •

When discarded, the fluid in the machine's individual systems and some of its parts become waste that could potentially cause damage to the environment.

This category of waste products includes, in particular: -

Organic and synthetic lube materials, oils and fuels

-

Coolants

-

Battery fluid and batteries

-

Detergents and preservatives

-

All removable filters and filter elements

-

All used or discarded hydraulic and fuel hoses, metals, rubbers and other elements of the machine that are contaminated with the aforementioned products.

•

When discarded, the indicated materials and parts must be handled according to applicable national regulations to protect individual elements of the environment and human health.

•

When removing hydraulic, fuel, or cooling systems and their units, prevent any fluid from leaking into the ground by putting protection underneath retention containers and plugging the openings. Use appropriate containers of a sufficient capacity.

•

If a leak occurs, use sawdust, Vapex or other means to dry the affected site.

•

Remove contaminated soil to prevent any further seepage. Hand over contaminated soil and absorbent for their safe disposal.

3-6

DV 207

SERVICE MANUAL 3.3. Fire measures •

The flammable liquids used in the machine have been divided into classes of risk based on fire hazard: Risk class II (Materials that must be moderately heated or exposed to relatively high ambient temperatures before they will ignite.)

-

Diesel

Risk class IV (Materials that will rapidly vaporize at atmospheric pressure and normal temperatures or are readily dispersed in the air and that burn readily.)

-

Mineral oils

-

Lubricating greases

-

Antifreeze

Oil exchange point •

The oil exchange point must be located so as not to interfere with the explosion or fire hazard areas.

•

The point must be labeled with “No Smoking” and “No Use of Open Flame“ notice boards and signs.

•

The oil exchange point must be equipped with portable fire extinguishers.

•

Dimension the handling area to be able to handle an amount of flammable liquid equal to the capacity of the largest vessel or shipping container.

•

Use vessels such as metal drums, jerry cans and tin cans when handling oil and diesel.

•

Make sure shipping containers are properly closed during storage.

•

Vessels must have one opening and must always be stored with the opening at the top and secured against any leakage (outflow) or dripping.

•

Vessels must be labeled with an indelible marking that states their content and flammability class.

The following is considered part of the machine's equipment: •

Vibration Roller Operator's Manual

•

Parts Catalog

•

Parts Catalog specific to the engine used

•

Engine Operating and Maintenance Manual specific to the engine used

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3-7

SECTION 00 – MAINTENANCE – CHAPTER 3 Notes

3-8

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SERVICE MANUAL

SECTION 00 – MAINTENANCE 4. Product identification

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4-1

SECTION 00 – MAINTENANCE – CHAPTER 4 4.1. Summary of applications Location of the production label 1 - Production label 2 - Machine’s production number 3 - ROPS cab label DV 207

CASE

LWA

106dB

Cummins engine serial number

Always state the data indicated in the table when contacting your dealer or manufacturer.

Please fill in the following data: Machine type .....................................................

Machine serial number (S/N) ...........................................

Year of the production ......................................

Engine type........................................................

Engine serial number.........................................

4-2

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SERVICE MANUAL

SECTION 00 – MAINTENANCE 5. Check the tightening of bolted joints

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5-1

SECTION 00 – MAINTENANCE – CHAPTER 5 5.1. Check the tightening of bolted joints •

Confirm regularly that bolted joints have not come loose.

•

Use torque wrenches for tightening.

TIGHTENING TORQUE For screws 8.8 (8G)

TIGHTENING TORQUE

For screws 10.9 (10K)

Thread size

Nm

M6

10

7.4

M8

24

25.0

M8x1

19

14.0

M10

48

35.4

M10x1.25

38

For screws 8.8 (8G)

For screws 10.9 (10K)

lb-ft

Thread size

14

10.3

M18x1.5

220

162.2

312

230.1

34

25.0

M20

390

287.6

550

405.6

27

19.9

M20x1.5

312

230.1

440

324.5

67

49.4

M22

530

390.9

745

549.4

28.0

54

39.8

M22x1.5

425

313.4

590

435.1

lb-ft

Nm

Nm

lb-ft

Nm

lb-ft

M12

83

61.2

117

86.2

M24

675

497.8

950

700.6

M12x1.25

66

48.7

94

69.3

M24x2

540

398.2

760

560.5

M14

132

97.3

185

136.4

M27

995

733.8

1400

1032.5

M14x1.5

106

78.2

148

109.1

M27x2

795

586.3

1120

826.0

M16

200

147.5

285

210.2

M30

1350

995.7

1900

1401.3

M16x1.5

160

118.0

228

168.1

M30x2

1080

796.5

1520

1121.0

M18

275

202.8

390

287.6

The values given in the table are torques at dry thread (at coefficient of friction = 0.14). These values do not apply to greased thread.

NOTE: Different tightening torques have been stated in relevant chapters.

Table with torques of cap nuts with O-ring – hoses Tightening torques for sliding nuts with O-ring – hoses Nm

lb-ft

Wrench size

Thread size

Hose

Nominal

Min

Max

Nominal

14

12x1.5

6

20

15

25

17

14x1.5

8

38

30

45

19

16x1.5

45

38

22

18x1.5

51

24

20x1.5

27

22x1.5

30

24x1.5

32

26x1.5

36 41 46 50 50

5-2

30x2 36x2

Min

Max

15

11

18

28

22

33

52

33

28

38

43

58

38

32

43

58

50

65

43

37

48

74

60

88

55

44

65

16

74

60

88

55

44

65

18

105

85

125

77

63

92

135

115

155

100

85

114

166

140

192

122

103

142

8 10 10 12 12 14 15

20 22 25 28

42x2

30

240

210

270

177

155

199

45x2

35

290

255

325

214

188

240

330

280

380

243

207

280

52x2

38 42

DV 207

SERVICE MANUAL

Tightening torques for flanges

Tightening torques for plugs

G -M

Nm

lb-ft

G -M

Nm

lb-ft

G 1/8

25

18

G 1/8

15

11

G 1/4

40

30

G 1/4

33

24

G 3/8

95

70

G 3/8

70

52

G 1/2

130

96

G 1/2

90

66

G 3/4

250

184

G 3/4

150

111

G1

400

295

G1

220

162

G 11/4

600

443

G 11/4

600

443

G 11/2

800

590

G 11/2

800

590

10 x 1

25

18

10 x 1

13

10

12 x 1.5

30

22

12 x 1.5

30

22

14 x 1.5

50

37

14 x 1.5

40

30

16 x 1.5

60

44

16 x 1.5

60

44

18 x 1.5

60

44

18 x 1.5

70

52

20 x 1.5

140

103

20 x 1.5

90

66

22 x 1.5

140

103

22 x 1.5

100

74

26 x1.5

220

162

26 x1.5

120

89

27 x 1.5

250

184

27 x 1.5

150

111

33 x 1.5

400

295

33 x 1.5

250

184

42 x 1.5

600

443

42 x 1.5

400

295

48 x 1.5

800

590

48 x 1.5

500

369

M-G

M-G

M-G

282N221T

DV 207

282N222T

5-3

SECTION 00 – MAINTENANCE – CHAPTER 5 Notes

5-4

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SERVICE MANUAL

SECTION 00 – MAINTENANCE GENERAL SPECIFICATIONS 6. Description of the machine

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6-1

SECTION 00 – MAINTENANCE – CHAPTER 6 6.1. Machine construction

14

17

15

12

16

18 11

13

20

5

20

21 6

7

4

21 1

3 9

2

8

10 19

21

21 406019

1 - Front frame

12 - Fuel tank

2 - Rear frame

13 - Sprinkling tank

3 - Front drum

14 - Cab with integrated ROPS arm

4 - Rear drum

15 - Driver's control panel

5 - Engine

16 - Battery

6 - Drum travel hydroelectric generator

17 - Combined engine and hydraulic oil cooler

7 - Drum vibration hydroelectric generator

18 - Air filter

8 - Travel hydraulic motor

19 - Exhaust pipe

9 - Vibration hydraulic motor

20 - Sprinkling jets

10 - Steering joint

21 - Drum scrapers

11 - Hydraulic tank

6-2

DV 207

SERVICE MANUAL 6.2. Fluid/lubricant specifications Viscosity diagram

6.2.1. Engine oil 2412

Engine oil has been specified as per its performance classification and viscosity classification.

o

F

C

o

122

50

104

40

86

30

68

20

50

10

32

0

14

10

4

20

22

30

40

40

Performance classification under AMERICAN PETROLEUM INSTITUTE (API)

The ambient temperature and type of operations at the site of machine use are decisive in determining the SOCIETY OF AUTOMOTIVE ENGINEERS (SAE) viscosity class.

Recommended oils:

15W-40

Viscosity classification

SAE 10W30: Winter SAE 5W30: Arctic API CI-4 oil is recommended Year-round: SAE 15W-40, refer to the viscosity diagram.

•

Exceeding the low temperature limit will not cause engine damage, but may cause some starting difficulties.

•

It is convenient to use universal multi-range oils to avoid the need to change oil due to ambient temperature.

•

It is possible to use a synthetic engine oil if the performance and viscosity classifications of the oil correspond to the recommended mineral oils.

•

The oil change intervals used must be the same as those for mineral oils.

•

To make starting at temperatures below 0°C (32°F) easier, the engine manufacturer recommends SAE 10W-30 oil.

5W-30

SAE 15W40: All seasons

10W-30

Case Akcela No. 1, 15W-40 Engine Oil:

400150

NOTICE Do not exceed the upper temperature limit for a prolonged period of time as this will reduce the capabilities of the oil.

When using oil API CG-4/SH, the oil change interval must be reduced by half, i.e. 125 hours.

DV 207

6-3

SECTION 00 – MAINTENANCE – CHAPTER 6 6.2.2. Fuel

WARNING Never mix diesel with gasoline or alcohol.

These mixtures may cause an explosion!

Failure to comply could result in death or serious injury.

Use fuel that complies with the ASTM (American Society for Testing and Materials) D975 standard: Grade no. 2 fuel

•

Fuel viscosity must be over 1.3 cST at 40°C (104°F) to ensure proper liquidity characteristics and proper lubrication of fuel system components.

NOTICE Check with your fuel supplier for the correct cold weather fuel.

General specification - biodiesel fuel Fatty Acid Methyl Ester (FAME) biodiesel, referred to as biodiesel fuel in the following section, is a family of fuels derived from vegetable oils treated with methyl esters.

NOTICE Biodiesel fuel blends are approved for your engine only if they comply with EN14214 specification standards or ASTM D6751.

NOTICE It is imperative that you check with your CASE dealer to find out which blend is approved for your engine. Be aware that use of biodiesel fuel that does not comply with the standards mentioned above could lead to severe damage to the engine and fuel system of your machine. The use of fuels that are not approved may void CASE warranty coverage.

Biodiesel fuel usage conditions

NOTICE The biodiesel fuel must comply with the fuel specification indicated above.

Biodiesel fuel must be purchased from a trusted supplier that understands the product and maintains good fuel quality. Biodiesel fuel must be preblended by the supplier. Mixing biodiesel fuels on-site could result in an incorrect mixture that could lead to problems with both the engine and the fuel system.

6-4

Engine performance is affected by the use of biodiesel fuel. There may be up to 12% reduction in power or torque depending on the blend used.

NOTICE DO NOT modify the engine and/or injection pump settings to recover the reduced performance.

The reduced power must be accepted if using any biodiesel fuel blend.

Some modification may be required to enable your engine to run on biodiesel fuel. Consult your dealer for complete information on these modifications.

Biodiesel fuel has a higher cloud point than diesel fuel.

NOTICE The use of high biodiesel fuel blends is not recommended in cold weather conditions.

With biodiesel fuels, it may be necessary to change the engine oil, engine oil filter and fuel filter elements more frequently than with diesel fuels. Biodiesel fuel can remove rust and particles from the inside of onsite fuel storage tanks that would normally adhere to the sides of the tank. Like particle deposits that commonly occur with diesel fuel, these particles can become trapped by the machine fuel filters, causing blockage and shortening filter life. This is more likely to happen in cold weather. Consult your CASE dealer for information on cold weather operation and proper maintenance intervals when using any biodiesel fuel blend.

When handling biodiesel fuel, be careful not to introduce water into the fuel supply. Biodiesel fuel attracts moisture from the atmosphere.

Keep fuel tanks as full as possible to limit the amount of air and water vapor. It may be necessary to drain the fuel filter water trap more frequently.

Potential oxidation and stability could be a problem with the fuel stored in the machine.

NOTICE Machines must not be stored for more than 3 months with biodiesel fuel blends in the fuel system.

If longer storage periods are necessary, the engine must run on pure diesel fuel for a minimum of 20 hours to flush the biodiesel fuel out of the fuel system prior to storage.

DV 207

SERVICE MANUAL 6.2.4. Hydraulic oil

NOTICE Biodiesel fuel must not be stored in on-site storage tanks for more than three months.

Any spillage of biodiesel fuel must be cleaned up immediately before it can cause damage to the environment and the paint finish of the machine.

Before using biodiesel fuel blends, consult your dealer to receive full information about the blend approved for your machine and any detailed conditions of its usage.

2158

Use only the following quality hydraulic oil of the correct performance class for the machine’s hydraulic system: Case Akcela Hy-Tran Ultra Synthetic hydraulic oil It is possible to fill the hydraulic system with synthetic oil for which any leakage will be completely biodegraded via microorganisms found in water and soil.

NOTICE Be aware that not fulfilling the requirements and conditions of biodiesel fuel usage will void your machine’s CASE warranty coverage.

NOTICE Always consult with the oil manufacturer or dealer before switching from mineral oil to synthetic oil or mixing oils of different brands!

6.2.5. Lube grease

6.2.3. Coolant

0787

2152

WARNING Hazardous nitroamines will form when a nitride-based antifreeze is mixed with an amine-based agent. Failure to comply could result in death or serious injury.

Use antifreeze in all seasons to protect the cooling system from corrosion and all risk of freezing.

For areas where ambient temperature is over -36°C (-32.8°F), use a blend of 50% ethylene-glycol based antifreeze.

For areas where the temperature is below -36°C (-32.8°F), it is advisable to use a blend of 40% water and 60% antifreeze.

NOTICE Do NOT use coolant with an antifreeze concentration greater than 50% (point of congelation is -36°C [-34°F], boiling point is 110°C [228°F]) unless absolutely required.

NEVER use an antifreeze concentration over 68%!

We do NOT recommend the blending of antifreeze agents. Blending various types of coolant may cause loss of anticorrosion properties.

Always check the antifreeze concentration of the coolant with a refractometer before the winter season starts.

DV 207

Use plastic lubricant with lithium content to lubricate the machine: CASE Akcela Extreme pressure grease moly

6.2.6. Washer fluid 2260

Use water (up to 0°C [32°F]) and motor vehicle glass washer fluid when filling the washer fluid reservoir.

NOTICE Fill with a winter-rated motor vehicle glass washer fluid when temperatures are below 0°C (32°F).

6.2.7. Gear oil 2186

Use high-quality fluid corresponding to Case Akcela 135H EP Gear Lube 80W-90 to lubricate the transmissions, pumps and drum reducers.

Use extreme pressure type fluid API GL-5 category SAE H80W-90 for outdoor temperature range -10°C-30°C (14°F-86°F).

NOTICE The operating temperature of the fluid must not exceed 85°C-90°C (185°F-194°F).

6-5

SECTION 00 – MAINTENANCE – CHAPTER 6 NOTE: All specifications are given according to SAE standards or recommended practices where the specification applies.

6.3. Technical data DV207 Weight Operating weight of CECE with cab, ROPS

kg (lb)

7360 (16230)

Operating load of CECE with cab, ROPS on front axis

kg (lb)

3750 (8270)

Operating load of CECE with cab, ROPS on rear axis

kg (lb)

3610 (7960)

Weight of half fluid capacities

kg (lb)

350 (770)

Operating weight of ISO 6016 with cab, ROPS

kg (lb)

7710 (17000)

Max. weight – cab + ROPS (6016) + accessories + weighing

kg (lb)

7910 (17440)

Maximum permitted weight according to ROPS

kg (lb)

9000 (19840)

Static linear load of front drum

kg/cm (lb/in)

27,5 (151,5)

Static linear load of rear drum

kg/cm (lb/in)

25.7 (141.7)

Cab weight

kg (lb)

650 (1430)

Weight of ROPS

kg (lb)

650 (1430)

Weight of sheet roof on ROPS

kg (lb)

70 (150)

Weight of cutter

kg (lb)

100 (220)

Weight of diagonal cutter

kg (lb)

200 (440)

km/h (MPH)

11.4 (7.1)

Climbing ability without vibration

%

30

Climbing ability with vibration

%

30

Lateral stability during driving with vibration

%

15

Lateral stability during driving without vibration

%

25

Lateral static stability

%

62,5

Turning radius outer (edge)

mm (in)

4600 (181.1)

Turning radius outer (contour)

mm (in)

6410 (252.4)

Type of drive

-

Hydrostatic

Number of driving axles

-

2

Oscillation angle

°

±8

Angle of steering

°

± 34

Type of steering

-

Joint

Steering control

-

Hydraulic

Linear hydraulic motors

-

2+1 (Crab)

Manufacturer

-

Cummins

Type

-

BTAA3.3-C80

Power according to DIN 6271

kW (HP)

60 (80)

Power according to ISO 3046/1

kW (HP)

60 (80)

-

4

cm (cu in)

3260 (198.9)

Driving characteristics Maximum transport speed

Steering

Engine

Number of cylinders Cylinder capacity 6-6

3

DV 207

SERVICE MANUAL Nominal speed HF

min-1 (RPM)

2200

Nominal speed

min (RPM)

2000

Maximum torque

Nm (ft lb)/rpm

304 (224)/1600

Routine operation fuel consumption

l/h (gal US/h)

10 (2.6)

Engines complies with emission regulations

-

97/68/EU Level 3, EPA/CARB 40 CFR Part 89 Tier 3

Cooling system of engine

-

Liquid

Operating

-

Hydrostatic

Parking

-

Mechanical multiple-disc

Emergency

-

Mechanical multiple-disc

Small amplitude

mm (in)

0.33 (0.012)

Large amplitude

mm (in)

0.6 (0.023)

Low frequency

Hz (VPM)

43 (2580)

High frequency

Hz (VPM)

52 (3120)

Low centrifugal force

kN

55 / 72

High centrifugal force

kN

65 / 80

High frequency HF

Hz (VPM)

62 (3720)

Low frequencyHF

Hz (VPM)

48 (2880)

Guaranteed sound power level A

Hz (VPM)

52 (3120)

-

Hydrostatic

Type of watering

-

Pressure

Number of pumps

-

2

Number of filtrations

-

3

Fuel

l (gal US)

110 (29.05)

Water for drum watering

l (gal US)

600 (158.5)

Engine (oil filling)

l (gal US)

7 (1.85)

Cooling system

l (gal US)

15 (3.96)

Hydraulic system

l (gal US)

40 (10.56)

Drum vibrator

l (gal US)

2x10,5 (2.77)

Vibrating drum front

l (gal US)

10,5 (2.77)

Vibrating drum rear

l (gal US)

10,5 (2.77)

Front watering tank

l (gal US)

600 (158.5)

Drum gearbox

l (gal US)

2x1,2 (0.32)

Washer tank

l (gal US)

2,75 (0.72)

Voltage

V

12

Battery capacity

Ah

100

-1

Brakes

Vibration

Type of drive

Watering

Fluid capacities

Wiring

DV 207

6-7

SECTION 00 – MAINTENANCE – CHAPTER 6

H

6.4. Dimensional diagram DV207

T

T

D

G

D

A

L

406015

6-8

A

C

D

G1

G

H

mm

3260

180

1150

965

240

3005

in

128.4

7.1

45.3

38

9.4

118.3

H1

L

T

W

W1

mm

2300

4410

15

1450

1550

in

90.6

173.6

0.6

57.1

61

DV 207

G1

H1

SERVICE MANUAL

W

C

W1

406016

DV 207

6-9

SECTION 00 – MAINTENANCE – CHAPTER 6 Notes

6-10

DV 207

SERVICE MANUAL

SECTION 00 – MAINTENANCE 7. Tooling

DV 207

7-1

SECTION 00 – MAINTENANCE – CHAPTER 7 7.1. Tooling and equipment Group

No. ND no.

Fixture name

Application

Drum (1)

1

ND148183

Handling suspension

Install/remove aux. transmission

2

ND090535

Stop

Lock drum position

3

ND090512

Handling clamp

Handle the drum

4

ND 090607

Nut adapter

Install/remove KM 22

5

ND 090607

Nut adapter

Install/remove KM 15

Steering joint (65)

6

ND 090607

Nut adapter

Install/remove KM 11

7

ND148181

Ring

Install/remove bearing 30

Hydraulic cylinders (65) 8

ND 101783

Split ring Ø 80

Install hydraulic cylinder piston

9

ND 101783

Split ring Ø 90

Install hydraulic cylinder piston

Fixture no. 1

ND148183

Fixture no. 2

ND090535 Fixture no. 3

ND090512 7-2

DV 207

SERVICE MANUAL Fixture no. 4 Fixture no. 5 Fixture no. 6

ND090607 Fixture no. 7

ND148181 Fixture no. 8 Fixture no. 9

ND101783

DV 207

7-3

SECTION 00 – MAINTENANCE – CHAPTER 7 Notes

7-4

DV 207

SERVICE MANUAL

SECTION 10 – ENGINE 8. Removing the engine

DV 207

8-1

SECTION 10 – ENGINE – CHAPTER 8

"

8-2

DV 207

SERVICE MANUAL 1)

Yoke

63)

Washer

2)

Yoke

64)

Washer

3)

Bracket

65)

Washer

4)

Bracket

66)

Washer

5)

Holder

67)

Spring washer

9)

Clip

68)

Spring washer

10)

Threaded rod

69)

Spring washer

11)

Intermediate piece

12)

Holder

13)

Contactor

15)

Connection

18)

Engine

19)

Pump

20)

Clutch

21)

Mounting flange

22)

Rubber mounting

23)

Thermostat

24)

Sealing ring

25)

Sealing ring

28)

Hollow screw

29 )

Hose

30)

Hose

31)

Hose

32)

Hose

33)

Hose clamp

35)

Hexagon head screw

36)

Hexagon head screw

37)

Hexagon head screw

38)

Hexagon head screw

39)

Hexagon head screw

40)

Hexagon head screw

41)

Hexagon head screw

42)

Hexagon head screw

43)

Hexagon head screw

44)

Hexagon head screw

47)

Stud

48)

Stud

52)

Hexagon nut

53)

Hexagon nut

54)

Hexagon nut

56)

Hexagon nut

57)

Hexagon nut

60)

Washer

61)

Washer

62)

Washer

DV 207

8-3

SECTION 10 – ENGINE – CHAPTER 8 Preparation work Position the roller in the left/right-hand lock to make it easier to remove the engine from the machine.

Drain the engine oil.

Remove the hood (refer to “13. Removing the hood”).

Remove the cooler (refer to “9. Removing the cooler”).

Remove the hydraulic hoses and wiring from the tandem pump. The tandem pump will remain mounted on the engine (refer to “11.3. Removing the tandem pumps for vibration and travel”)

Remove joining strips.

Remove the hose clamp.

400A115 Remove coolant pipes.

400A116

400A117 8-4

DV 207

SERVICE MANUAL Remove the accelerator control cable.

400A118 Remove the hoses from their holder. Remove the hose clamp.

400A121 Detach the fuel overflow hose from the engine; collect any fuel spill.

400A119 Detach the fuel supply pipe from the filter.

400A120 DV 207

8-5

SECTION 10 – ENGINE – CHAPTER 8 Detach the pipe from the flushing block.

400A122 Remove the pipe.

400A294 Remove the intake pipe from the steering pump. We recommend replacement of the sealing ring.

400A124 Remove the discharge side pipe from the steering pump. We recommend replacement of the sealing ring.

" 8-6

DV 207

SERVICE MANUAL Remove the hose leading from the steering block to the cooling hydromotor.

" Disconnect the wiring of the hydraulic oil level and temperature gauges.

400A127 Disconnect the engine rpm sensor wiring.

400A128 Remove the holder with steering block.

400A129 DV 207

8-7

SECTION 10 – ENGINE – CHAPTER 8 Swing the steering block from the frame.

400A130 Disconnect the wiring from the battery terminal.

400A131 Detach hoses from the cube.

400A132 Detach the air pipe.

400A133 8-8

DV 207

SERVICE MANUAL Detach the exhaust pipe and lift it off.

400A134 Unplug the connector and disconnect the engine ground connection.

400A135 Disconnect the starter motor wiring.

400A136 Detach the coolant pipe.

400A137 DV 207

8-9

SECTION 10 – ENGINE – CHAPTER 8 Remove the turbocharger flange.

400A138 Disconnect the wiring of the preheating and starter motor contactors.

400A139 Detach the oil filter holder and lift it off.

400A139A

8-10

DV 207

SERVICE MANUAL Remove the bracket of the engine rubber mounting (3x).

400A140

400A141 Suspend the engine in a hoisting device with a 700 kg (1543 lb) load capacity and take it out. Position the engine on a pedestal with sufficient load capacity.

400A142 NOTE: When replacing the engine, adjust max engine rpm. Do NOT adjust idle speed (800 rpm).

Max rpm with no load: Machine with CE: 2100 ± 20 rpm Machine with no CE: 2200 ± 20 rpm (at the lower pulley the idle speed is 800 ± 20 rpm).

Set engine speed by adjusting the stop screw on the injection pump. Be careful not to break off the counter nut! Adjust with the engine stopped, at operating temperature and with no load.

400A285 DV 207

8-11

SECTION 10 – ENGINE – CHAPTER 8 Notes

8-12

DV 207

SERVICE MANUAL

SECTION 10 – ENGINE 9. Removing the cooler

DV 207

9-1

SECTION 10 – ENGINE – CHAPTER 9

"@"

9-2

DV 207

SERVICE MANUAL 1)

Box

3)

Holder

4)

Exhaust manifold

5)

End fitting

8)

Pipe

9)

Yoke

10)

Connector

15)

Filter

16)

Holder

17)

Indicator

18)

Exhaust

19)

Manifold

23)

Hose

24)

Hose

27)

Clip

28)

Clip

29)

Hose clamp

30)

Clip

31)

Hose clamp

33)

Insulating tape

37)

Hexagon head screw

38)

Hexagon head screw

42)

Hexagon nut

43)

Hexagon nut

47)

Washer

48)

Washer

DV 207

9-3

SECTION 10 – ENGINE – CHAPTER 9

4-07680A_A_

9-4

DV 207

SERVICE MANUAL 2)

Pipe

74)

Washer

3)

Holder

75)

Washer

7)

Bar

77)

Washer

8)

Bar

78)

Washer

9)

Plate

79)

Spring washer

10)

Radiator bracket

11)

Radiator bracket

12)

Radiator bracket

13)

Radiator bracket

14)

Washer

16)

Pipe

17)

Pipe

18)

Pipe

20)

Radiator

21)

Fluid motor

22)

Fan

25)

Rubber mounting

26)

Profile

27)

Profile

28)

Hose

29)

Hose

30)

Hose

31)

Hose

34)

Manifold

35)

Reduction

36)

Clutch

39)

Banjo union

42)

Clip

43)

Hose clamp

44)

Hose clamp

45)

Hose clamp

46)

Hose clamp

50)

Plug

52)

Plug

58)

Hexagon head screw

59)

Hexagon head screw

60)

Hexagon head screw

61)

Socket head cap screw

62)

Hexagon head screw

63)

Hexagon head screw

64)

Hexagon head screw

66)

Hexagon head screw

67)

Hexagon head screw

69)

Hexagon nut

70)

Hexagon nut

DV 207

9-5

SECTION 10 – ENGINE – CHAPTER 9 Preparation work Drain coolant.

Remove the hood (refer to chapter “13. Removing the hood”).

Disconnect the wiring of the vacuum air switch.

23

Remove the air filter (15) and the hoses (23, 24).

24

15 400A288 Detach the air pipe.

400A143 Detach the air pipe.

NOTE: When detaching, seal all air holes.

400A144 9-6

DV 207

SERVICE MANUAL Detach the hydraulic oil pipe from the cooler and blind it.

400A145 Detach the hydraulic oil pipe from the cube, drain the hydraulic oil into a receptacle and blind the pipe.

400A146 Detach the coolant hose from the cooler surface.

400A147 Detach the return hose from the cooler from underneath the engine.

400A148 DV 207

9-7

SECTION 10 – ENGINE – CHAPTER 9

400A149 Remove the air filter holder.

400A150 Remove the grille.

400A151 Remove the center bolts of the cooler.

400A152 9-8

DV 207

SERVICE MANUAL Mount lifting lugs and sling onto the crane. Remove the other bolts of the cooler mounting. Lower the cooler onto the engine.

400A153 Remove the top rubber mountings on both sides.

400A154 Mount lifting lugs, hang onto the crane, lift carefully and move aside.

400A155 Remove the upper bar.

400A156 DV 207

9-9

SECTION 10 – ENGINE – CHAPTER 9 Remove the lower bar.

400A157 Remove the cooler clip on both sides.

400A158 Remove the bolts of the cooler mounting.

400A159 Take out the cooler.

NOTE: After the clips have been removed, take out the hydraulic oil and the coolant coolers.

400A160 9-10

DV 207

SERVICE MANUAL

SECTION 35 – HYDRAULIC SYSTEM 10. Hydraulic system

DV 207

10-1

FRONT

REAR

1

1

A

25

B

A

25

B

2

2

A

C

B

D

3

2

3

2

1

1

5

Dn16

200

MA

MB

M3

P2

T

Dn10

Dn10

A

B

MA

330

330

MB E M3

P1

13 l/min

C1

L2

45

22

400

400

C1

S1

S2

C2

L2 M5 M4 L1 Dn16 Dn10

Dn13 Dn13

M5 M4

C2

2

P

78

T

MB

B

T

1 MPa E

26

M3

13 l/min Dn10 MA

L3

MB L4 L1

Dn10

Dn10

MA

A

Dn10 Dn10 A

B

2200 ot/min

Dn16

3

35

28 30 1

3 bar

18

P

P1

Dn13 i=1.0

29

22 27

15

23

100

11

17

S

420

420

1,2 mm

24

°C

C

A

3 bar

30 D

9.5

180

20

°C

55°C

Dn14

Dn16

Dn16

25

40°C

8 19

Dn16 Dn10

30 A

D

26

P

20

Dn10

LD

100

Ø0.5 mm

Dn13

Dn13

175

400

T

Dn13

11

21

31

Ø0.5 mm

Dn8

Dn13

Dn13

Dn13

L

240

R

80/40-200

80/40-200

Dn13

240

Dn13 Dn13

12 17 9

10

Dn10

Dn10 Ø1 mm

90/45-125

14

M

P1

X

T1

B2 A2

B1 A1

100

CRAB

16

P

2.7 bar

5

3.5 bar

190

100

B A

100

T P

32

PP

EDGE CUTTER B A

Dn8

FRONT RIGHT HYDROMOTOR Dn19

Dn16 Dn10

Dn8

REAR LEFT HYDROMOTOR Dn19

B

Dn13

Dn16 Dn8

B

Dn6

B

Dn6

7

Dn16

Dn16

0.5 bar

0.5 bar

Dn16

Dn16

Dn13

Dn32

Ø25 - 230 Dn6 Dn6 Dn6

Ø25 - 230

A

50/25-130

T P

10-2 Dn16

6

T2

20 bar

A5

T3

13 bar

A4

SECTION 35 – HYDRAULIC SYSTEM – CHAPTER 10

211391en

DV 207

Dn10

1 MPa

3 bar

0.5 bar

SERVICE MANUAL 10.1. Hydraulic diagram Legend: 1.

Travel pump

2.

Vibration pump

3.

Steering and cooling pump

5.

Vibration and purging block

6.

Travel hydraulic motor

7.

Vibration hydraulic motor

8.

Cooling hydraulic motor

9.

Steering hydraulic motor

10. Crab hydraulic motor 11. Lifting hydraulic motor 12. Edge cutter hydraulic motor (option) 14. Power-assisted steering 15. Flow divider 16. Filter 17. Steering block 18. Flushing (purging) block 19. Cooler (combination type) 20. Hydraulic tank 21. Hand pump 22. Thermoregulator 23. Intake strainer 24. Filler neck 25. Level indicator 26. Oil gauge 27. Check valve 28. Check valve 29. Temperature switch 85±3°C (181.4±5.4°F) 30. Ball valve 31. Ball valve 32. Quick coupling, filling type 35. Quick coupling, measuring type

DV 207

10-3

SECTION 35 – HYDRAULIC SYSTEM – CHAPTER 10 Notes

10-4

DV 207

SERVICE MANUAL

SECTION 35 – HYDRAULIC SYSTEM 11. Hydraulics

DV 207

11-1

SECTION 35 – HYDRAULIC SYSTEM – CHAPTER 11

20

63 14 22 79 67 79 67

70 75

3

79 67

21

61

4-07680A_A

11-2

DV 207

SERVICE MANUAL 3)

Holder

14)

Washer

21)

Fluid motor

22)

Fan

61)

Socket head cap screw

63)

Hexagon head screw

67)

Hexagon head screw

70)

Hexagon nut

75)

Washer

79)

Spring washer

DV 207

11-3

SECTION 35 – HYDRAULIC SYSTEM – CHAPTER 11 11.1. Removing hydromotor

the

cooling

Disconnect the wiring of the vacuum air switch.

Remove the air filter (15) and the hoses (23, 24).

23 24

15 400A288 Detach the holder for the cooling air fan (3) and lift it off.

Remove the bolt (63) of the cooling air fan mounting.

Remove the screw (61) securing the hydromotor to the grille.

400A287 NOTE: Position a containment tank under the hydrometer.

Mark and remove the hydromotor hoses.

400A094

11-4

DV 207

SERVICE MANUAL Notes

DV 207

11-5

SECTION 35 – HYDRAULIC SYSTEM – CHAPTER 11

"

11-6

DV 207

SERVICE MANUAL 1)

Clip

6)

Flange

7)

Flange

8)

Connector

9)

Connector

10)

Connector

11)

Adjustable male stud run

13)

T-socket

14)

Eye

15)

Flow control screw

18)

O-ring

24)

Yoke

30)

Hexagon nut

31)

Hexagon nut

35)

Washer

40)

Staple strip

50)

Hose

51)

Hose

52)

Hose

54)

Hose

55)

Hose

57)

Hose

58)

Hose

59)

Hose

60)

Hose

61)

Hose

62)

Hose

DV 207

11-7

SECTION 35 – HYDRAULIC SYSTEM – CHAPTER 11 11.2. Removing the gear pump for steering Mark and remove the hoses.

400A095 Remove the flanges. Remove the bolts of the mounting. Shift out the pump.

NOTE: We recommend replacement of the sealing ring.

400A096

11-8

DV 207

SERVICE MANUAL Notes

DV 207

11-9

SECTION 35 – HYDRAULIC SYSTEM – CHAPTER 11

"@"

11-10

DV 207

SERVICE MANUAL 1)

Plate

103)

Yoke

3)

Holder

107)

Sealing ring

4)

Threaded rod

110)

O-ring

7)

Filter

118)

Hexagon head screw

8)

Hydraulic vibrating block

119)

Hexagon head screw

9)

Block

121)

Hexagon head screw

10)

Block

122)

Hexagon head screw

12)

Temperature switch

123)

Socket head cap screw

14)

Hydraulic body

124)

Hexagon head screw

15)

Hydraulic body

137)

ST Washer

21)

Connector

138)

ST Spring washer

22)

Connector

139)

ST Washer

25)

Connector

141)

Spring washer

27)

Connector

144)

Hexagon nut

30)

Connector

31)

Connector

34)

Connector

35)

Connector

37)

Connector

38)

Connector

40)

Connector

41)

Connector

46)

Adjustable male stud run

47)

Manifold

48)

Manifold

49)

Adjustable male stud run

52)

T-socket

53)

T-socket

55)

T-socket

58)

Clutch

60)

Reduction

64)

Hose

65)

Hose

66)

Hose

68)

Hose

69)

Hose

70)

Hose

71)

Hose

72)

Hose

73)

Hose

77)

Hose

90)

Quick coupling

91)

Quick coupling

92)

Quick coupling

97)

Cover

DV 207

11-11

Y8

Y4

Y5

Y9

SECTION 35 – HYDRAULIC SYSTEM – CHAPTER 11

4-10919A

11-12

DV 207

SERVICE MANUAL 1)

Pump

2)

Pump

4)

Screw

5)

Hexagon head screw

7)

Spring washer

9)

O-ring

DV 207

11-13

SECTION 35 – HYDRAULIC SYSTEM – CHAPTER 11 11.3. Removing the tandem pumps for vibration and travel 11.3.1. Vibration pump NOTE: Disconnect the battery. Place a containment tank under the pumps, blind the hoses and outlets once removed.

Drain the hydraulic oil (40 l/10.5 US gal).

400624 Disconnect the wiring of the vacuum air switch.

Remove the air filter (15) and the hoses (23, 24).

23

Remove the straps.

24

15 400A288 Remove the clamp and release the hoses.

400A097 11-14

DV 207

SERVICE MANUAL Mark and remove the hoses from block 8. Mark and disconnect the connectors (Y10, Y11).

Y10

Y11 400A098 Detach the hoses from the cubes (1, 2).

400A099 Remove the block. We recommend replacement of the sealing rings.

400A100 Detach the hoses from the vibration pump and disconnect the wiring connectors (Y8, Y9).

Y9 400A101 DV 207

11-15

SECTION 35 – HYDRAULIC SYSTEM – CHAPTER 11 Suspend the vibration pump on the hoisting apparatus.

Remove the two bolts of the pump mounting. Shift out the pump and lower it below the frame. We recommend replacement of the sealing ring.

NOTE: When reinstalling, clean the contact surfaces, use Loctite to cement the bolts and torque tighten to 83 Nm (61 lb-ft).

400A102

11.3.2. Travel pump Perform the operations indicated in chapter “11.3.1.

Vibration pump”.

1

2

NOTE: Leave the vibration pump mounted on the travel pump.

Remove the hose from the travel pump. Remove the cubes (1, 2). We recommend replacement of the sealing ring. Mark and disconnect connectors Y4, Y5.

400A103 Suspend the pumps from the crane.

400A105 Remove the grub screws from the pump.

Remove bolts used to mount the travel pump to the engine. Shift out the pumps and lower them below the frame. We recommend replacement of the sealing ring.

NOTE: When reinstalling, clean the contact surfaces, use Loctite to cement the screws and torque tighten to 132 Nm (97 lb-ft).

400A104 11-16

DV 207

SERVICE MANUAL Remove the coupling.

NOTE: When reinstalling, clean the contact surfaces and torque tighten to 86 Nm (64 lb-ft).

400A106 With the pump connected, torque tighten the bolts to 83 Nm (61 lb-ft).

400A107 Remove the flange.

NOTE: When reinstalling, clean the contact surfaces and torque tighten to 48 Nm (35 lb-ft).

400A109 Remove the coupling.

NOTE: When reinstalling, clean the contact surfaces and torque tighten to 48 Nm (35 lb-ft).

400A109 DV 207

11-17

SECTION 35 – HYDRAULIC SYSTEM – CHAPTER 11 11.4. Adjusting vibration frequency To adjust vibration, check and, if necessary, adjust max. engine rpm. (refer to “8. Removing the engine””.

Check frequency values with the roller at standstill and placed on a test bench, or on tires laid down or on a soft surface at max engine speed (adjusted to 2100/2200). Position the gauge probe on the drum mantle and turn vibration ON at the measured drum only.

401D275

NOTICE The maximum total vibrator run time with no drum rotation (to lubricate bearings) is 2 minutes!!!

Or position the gauge probe on the damper plate.

When measuring this way, you can scan vibrator frequency while driving the machine.

401D276 Use Allen screws to adjust vibrator frequency (1) (low amplitude) and (2) (high amplitude) with the locking nut loosened.

Loosening (turning counterclockwise) increases frequency and vice versa. Start the engine and check the set value again with the engine running.

Vibration frequency set values

2

Roller has “CE” certification Amplitude

low

52 -0.5 Hz (3120-30 VPM)

Amplitude

high

43 -0.5Hz (2580-30 VPM) 400A274

Roller has no “CE” certification Amplitude

low

62 -0.5 Hz (3720-30 VPM)

Amplitude

high

48 -0.5Hz (2880-30 VPM)

WARNING Adjust vibration frequency with the engine turned OFF!

1

Failure to comply could result in death or serious injury.

400A275 11-18

DV 207

SERVICE MANUAL 11.5. Adjusting pulse sensors The pulse sensor must be adjusted any time the travel hydromotor sensor is replaced.

400A290 Location of pulse sensor on the machine (front drum)

400A291 Proceed as follows when to adjust sensors: Install pulse sensor to the stop in the travel hydromotor so it touches the ring gear.

400A293 Turn the pulse back one turn so that the distance between the pulse sensor and the ring gear is 0.1-2 mm (0.004 to 0.08 in). See Figure.

Sensor – ensure the nuts and gaskets are tightened to torque.

3JOH HFBS *NQVMTF TFOTPS

Tighten the nut to maximum 12 Nm (9 lb-ft).

NN JO

" DV 207

11-19

SECTION 35 – HYDRAULIC SYSTEM – CHAPTER 11 11.6. Measuring hydraulic circuit safety pressures Travel pressure MA – Backward drive 42 Mpa 420 bar (6090 PSI) MA

MB – Forward drive 42 Mpa 420 bar (6090 PSI) MB

400A269 Vibration pressure MA – Low amplitude 36 Mpa 360 bar (5220 PSI) MB – High amplitude 36 Mpa 360 bar (5220 PSI)

MA

MB

400A270 Cooling pressure Additional pressure 20 Mpa 200 bar (2900 PSI)

400A289 Steering pressure, crab, edge cutter M – 23 Mpa 230 bar (3335 PSI) NOTE: After hydrometer replacement or repair, ATC control unit parameters for machine travel must be set and vibration frequency must be adjusted. Contact your nearest dealer for help in setting ATC control unit parameters! Refer to section “11.4. Adjusting vibration frequency” to adjust vibration parameters of the machine.

M 400A272

11-20

DV 207

SERVICE MANUAL

SECTION 39 – FRAMES 12. Articulated joint

DV 207

12-1

SECTION 39 – FRAMES – CHAPTER 12

"@"

12-2

DV 207

SERVICE MANUAL 1)

Steering suspension

2)

Arm

3)

Holder

5)

Pipe

6)

Cam

7)

Bolt

8)

Split pin

9)

Bolt

10)

Cap

11)

Cap

12)

Cap

13)

Cap

14)

Bolt

15)

Bolt

16)

Ring

17)

Ring

18)

Plate

19)

Plate

20)

Arm

22)

Washer

26)

Fluid motor

27)

Fluid motor

28)

Bearing

29)

Bearing

30)

Bearing

31)

Stripper ring

32)

O-ring

33)

Profile

35)

Nut

36)

Plate

37)

Circlip

40)

Hexagon head screw

41)

Hexagon head screw

42)

Hexagon head screw

43)

Hexagon head screw

44)

Hexagon head screw

46)

Hexagon head screw

51)

Washer

52)

Washer

53)

Washer

54)

Washer

55)

Spring washer

56)

Spring washer

59)

Grease nipple

60)

Grease nipple

DV 207

61)

Grease nipple

12-3

SECTION 39 – FRAMES – CHAPTER 12 12.1. Preparation work NOTICE Turn off the master switch.

Remove the cover.

400A190 Remove the clamp.

400A191 Detach and blind the engine hose.

NOTE: Collect coolant from the heater.

400D192

400A193 12-4

DV 207

SERVICE MANUAL Remove the cab rubber mountings (2x).

-

Left-hand side

400A194 -

Right-hand side

400A195 Remove the instrument board cover.

400A196 Remove the grommet.

400A197 DV 207

12-5

SECTION 39 – FRAMES – CHAPTER 12 Disconnect the cab connector.

400A198

400A199 Mark and remove the cab ground connection.

400A200 Remove the accelerator control cable.

400A201 12-6

DV 207

SERVICE MANUAL Remove the instrument board. Mark and disconnect connectors for clusters.

400A202 Mark and detach the power steering hoses and blind the hoses.

400A203 Suspend the cab on a crane.

400A204 Remove the crossmember bolts.

400A205 DV 207

12-7

SECTION 39 – FRAMES – CHAPTER 12 Remove the hose clamp.

400A206 Remove the grommet of the power steering hoses.

400A207 Lift the cab slightly, pull through the connector and hoses of the cab and move the cab aside.

400A208 Disconnect the wiring for the alarm for water level in the tank.

400A209 12-8

DV 207

SERVICE MANUAL Detach the supply hose from the water tank.

400A210 Fit lifting lugs on both sides.

400A211

400A212 Remove the water tank mounting.

400A213 DV 207

12-9

SECTION 39 – FRAMES – CHAPTER 12 Suspend the water tank on a crane, lift it and move it aside.

400A214 Remove the cover.

400A215

12.2. Removing the steering joint Remove the hose holder.

400A216 Remove the steering unit packing pieces (18).

-

Front one

18

400D217 12-10

DV 207

SERVICE MANUAL -

Rear one

18

400D218 Press out the pins (14).

400A219 Mark, detach and blind the hoses.

Detach the hydraulic cylinder and move it aside.

400A220 Remove the CRAB hydraulic cylinder in the same manner. Remove packing pieces (19). Press out the pins (15). Mark, detach and blind the hoses.

400A221 DV 207

12-11

SECTION 39 – FRAMES – CHAPTER 12 Support the front frame and rear frame on both sides.

400A222 Secure the rear drum against any motion.

2

400A226 Support the steering unit to remove the bearing bolts.

400A223 Remove the bolts (46) of the bearing (28).

400A224 12-12

DV 207

SERVICE MANUAL Remove joining strips and take out hoses. Remove the holder (3) and line (5).

3

5

400A225 Brake off the roller. Refer to the Operator's Manual.

Use levers (1) and (2) to move away the front frame.

2

1

400D227 Secure the front drum against any motion.

2

400A228 Swing the steering joint to the right and slacken two bolts.

NOTE: The bolts were torque tightened to 900 Nm (664 lb-ft).

400A229 DV 207

12-13

SECTION 39 – FRAMES – CHAPTER 12 Swing the joint to the left.

400A230 Remove the clip for position sensors. Do not remove the sensors!

NOTE: After restoring the machine to its original condition, adjust the zero position of the steering joint (refer to “12.6. Adjusting the zero position of the steering joint”).

400A231 Remove the cam (6).

6 400A232 Slacken the two bolts used to secure the joint.

NOTE: The bolts are torque tightened to 900 Nm (664 lb-ft).

400D233 12-14

DV 207

SERVICE MANUAL Support the joint.

400A234 Remove the upper stirrup.

400A235 Suspend the joint from a crane, remove the lower stirrup and lower the joint below the frame. Shift out the joint.

400A236

12.3. Removing the slewing ring bearing Remove the bearing.

400A237 DV 207

12-15

SECTION 39 – FRAMES – CHAPTER 12 NOTE: When reinstalling, position the hole against the gap on the slewing ring. Fill the bearing with grease via four lubricating points.

400A238

12.4. Removing the steering joint bearing

10

Remove the cover (10).

400A239 Unlock the KM nut (35).

35

400A240 12-16

DV 207

SERVICE MANUAL Use fixture no. [6] to remove the KM nut.

6

400A241 Turn the arm (see figure). Remove the cover (13).

13

400A242 Attach the cover (12) with four screws (42).

42

12

400A243 Drive out the pin (9). Remove the fixing of cover (12) with four screws (42).

42

12 9 400A244 DV 207

12-17

SECTION 39 – FRAMES – CHAPTER 12 Turn the arm (see figure). Remove the cover (12) from the pin along with scraper ring (31). Press out the bearing (30).

30

400A245 Use fixture no. [7] and puller to pull down the second bearing (30).

7 400A246 Drive the pin (9) out of the arm.

9 400A247

12-18

DV 207

SERVICE MANUAL 12.5. Installing the steering joint bearing Clean contact surfaces of the arm (2) and covers (10, 11, 12, 13).

400A248 Insert the pin (9) and covers (11, 12) complete with scraper rings (31). Tap the bearing (30) into the arm.

30

11

31 9

31

12 400A249 Turn the arm and tap the pin (9) farther into the bearing.

9

400A250 Tap the bearing into place.

400A251 DV 207

12-19

SECTION 39 – FRAMES – CHAPTER 12 Lubricate the bearing and apply caulking compound (Lukopren) to the contact surfaces.

400A252 Use screw (42) to install the covers (12, 13).

13

12

400D253 Turn the arm and tap the bearing more.

400A254 Tap the pin (9) farther into the lower bearing.

400A255 12-20

DV 207

SERVICE MANUAL Use the fixture to fit the KM nut (35) and secure with locking steel sheet (36).

35 36

NOTE: Torque tighten the KM nut (35) to 100 Nm (74 lb-ft).

400A256 Lubricate the bearing and apply caulking compound (Lukopren) to the contact surfaces.

400A257 Use screw (42) to install the covers (10, 11).

Follow the steps in reverse order to install the joint in the machine.

10

11

400D258

DV 207

12-21

SECTION 39 – FRAMES – CHAPTER 12 12.6. Adjusting the zero position of the steering joint Use the batten, positioned full length to the machine side, to level the machine (front and rear drum in one track).

400A277

Adjust 1 mm (0.039 in) gap between the sensors and cam.

400A278 Turn the key in the ignition switch to the “I” (ON) position (crab indicator lamp and indicators on position pick-ups will light).

Adjust the position of pick-ups (1) and (2) against cam (3) (indicators on both pick-ups and the position indicator lamp must go OFF). See figure.

A

3 1 2

400A279 Adjustment – component A 1mm (0,039 in)

1mm (0,039 in)

400A280 12-22

DV 207

SERVICE MANUAL

SECTION 39 – FRAMES 13. Removing the hood

DV 207

13-1

SECTION 39 – FRAMES – CHAPTER 13

4-11090A

13-2

DV 207

SERVICE MANUAL 1)

Cover hood

60)

Hexagon nut

2)

Suspension

61)

Hexagon nut

3)

Suspension

62)

Hexagon nut

4)

Arm

65)

Washer

5)

Arm

66)

Washer

6)

Diaphragm

67)

Washer

7)

Diaphragm

68)

Spring washer

8)

Supporting pillar

69)

Washer

12)

Arm

72)

Clip

13)

Grille

14)

Grille

15)

Door

16)

Washer

17)

Plate

18)

Bolt

20)

Insulation

21)

Insulation

22)

Hood insulation

23)

Insulation

24)

Insulation

25)

Insulation

26)

Rubber guard plate

27)

Washer

28)

Washer

29)

Washer

31)

Fluid motor

32)

Bush

33)

Tongue lock

34)

Suspension

35)

Profile

37)

Rubber profile

38)

Rubber mounting

39)

Rubber mounting

40)

Grease nipple

41)

Sealing tape

46)

Circlip

47)

Grease nipple

48)

Grease nipple

51)

Hexagon head screw

52)

Hexagon head screw

53)

Hexagon head screw

54)

Hexagon head screw

55)

Oval head countersunk screw

56)

Oval head countersunk screw

59)

Nut

DV 207

13-3

SECTION 39 – FRAMES – CHAPTER 13 NOTE: Lift the hood and secure it with the strut!

Install the lifting lugs.

" Remove the shutters (7).

7

7

400A111 Remove the grille (14) on both sides.

14

400A112 Suspend the complete hood from the crane.

" 13-4

DV 207

SERVICE MANUAL Remove the screws of the part (3).

Lift the hood and move it aside.

3

400A114

Removing hydraulic cylinders (plungers) for hood lifting Remove the hood (refer to “13. Removing the hood”).

Remove the packing piece.

400A281 Drive out the pin of the piston rod eyelet.

Move aside the lifting arm and hydraulic cylinder on the cylinder frame. Support the piston rod to prevent its surface from becoming damaged.

400A282 Remove the safety ring and grease nipple.

400A283 DV 207

13-5

SECTION 39 – FRAMES – CHAPTER 13 Use lever (1) to carefully slip the hydraulic cylinder out of the pin.

Remove the hose from the hydraulic cylinder.

1 400A284

13-6

DV 207

SERVICE MANUAL

SECTION 41 - STEERING 14.

DV 207

Steering cylinder

14-1

SECTION 41 – STEERING – CHAPTER 14

"@"

14-2

DV 207

SERVICE MANUAL 1)

Steering suspension

2)

Arm

3)

Holder

5)

Pipe

6)

Cam

7)

Bolt

8)

Split pin

9)

Bolt

10)

Cap

11)

Cap

12)

Cap

13)

Cap

14)

Bolt

15)

Bolt

16)

Ring

17)

Ring

18)

Plate

19)

Plate

20)

Arm

22)

Washer

26)

Fluid motor

27)

Fluid motor

28)

Bearing

29)

Bearing

30)

Bearing

31)

Stripper ring

32)

O-ring

33)

Profile

35)

Nut

36)

Plate

37)

Circlip

40)

Hexagon head screw

41)

Hexagon head screw

42)

Hexagon head screw

43)

Hexagon head screw

44)

Hexagon head screw

46)

Hexagon head screw

51)

Washer

52)

Washer

53)

Washer

54)

Washer

55)

Spring washer

56)

Spring washer

59)

Grease nipple

60)

Grease nipple

DV 207

61)

Grease nipple

14-3

SECTION 41 – STEERING – CHAPTER 14 14.1. Removing hydraulic cylinders for steering and CRAB Remove packing pieces (19).

-

Rear one

400A218 -

Front one

400A264 Press out the pins of the hydraulic cylinder eyes. Take the hydraulic cylinder for steering out of the brackets.

400A219 Mark and remove the hydraulic hose connection.

Remove the CRAB hydraulic cylinder in the same manner.

NOTE: Only remove hydraulic cylinders that must be repaired or replaced.

400A220 14-4

DV 207

SERVICE MANUAL 14.2. Replacing packing material for steering or Crab hydraulic cylinders Packing material kit Pos.

1

1

1

6

6

3

Name

1

Gasket

2

Cuff

3

Scraper ring

4

Guide strip

5

Ring

6

Ring

2

5

5

4

4 401D258

NOTE: Relevant packing material can be ordered from the manufacturer.

The following steps are identical for the removal of hydromotors indicated above.

Unlock the hydraulic motor cover.

348D5499 Remove the hydraulic motor cover using the hook spanner.

348D5522 DV 207

14-5

SECTION 41 – STEERING – CHAPTER 14 Take it out.

348D5523 Take out the hydraulic motor piston.

348D5524 Remove the piston nut and recaulk the piston together with the cover.

348D5525 Install fixture no. [8] in the hydraulic motor body.

8

400A276 14-6

DV 207

SERVICE MANUAL Slip the piston over.

348D5530 Remove the fixture from the hydraulic motor.

348D5531 Install the hydraulic motor cover.

348D5500 Lock the cover.

348D5501 DV 207

14-7

SECTION 41 – STEERING – CHAPTER 14 Torque chart -

Values are for information purposes only

Hydraulic cylinder for steering 80/40-200

Connection: piston rod 2, piston 3, nut 4

Connection: cylinder body 1, cylinder cover 5

Thread

Torque

Thread

Torque

M30x2

130 [96]

M85x1.5

180 [133]

Hydraulic cylinder for crab 90/45-125

Connection: piston rod 2, piston 3, nut 4

Connection: cylinder body 1, cylinder cover 5

Thread

Torque

Thread

Torque

M32x2

140 [103]

M95x1.2

200 [148]

Hydraulic cylinder 1

cylinder body

2

piston rod

3

piston

4

nut

5

cover

%

14-8

DV 207

SERVICE MANUAL

SECTION 44 – AXLES AND WHEELS 15.

DV 207

Removing the drum

15-1

SECTION 44 – AXLES AND WHEELS – CHAPTER 15

4-10228A_A

15-2

DV 207

SERVICE MANUAL 1)

Yoke

2)

Yoke

3)

Transverse beam

4)

Plate

6)

Cover

7)

Spacer washer

8)

Spacer washer

9)

Venting valve

10)

Connector

11)

Hose

12)

Rubber mounting

15)

Hexagon head screw

16)

Hexagon head screw

17)

Hexagon head screw

18)

Hexagon head screw

19)

Hexagon head screw

22)

Hexagon head screw

28)

Hexagon nut

30)

Nut

35)

Spring washer

36)

Washer

37)

Spring washer

39)

Washer

40)

Washer

50)

Plug

DV 207

15-3

SECTION 44 – AXLES AND WHEELS – CHAPTER 15

4-10201A

15-4

DV 207

SERVICE MANUAL 1)

Drum

2)

Left cover

3)

Right cover

6)

Cover

7)

O-ring

8)

O-ring

9)

Plug

10)

Plug

16)

Hexagon head screw

17)

Hexagon head screw

18)

Hexagon head screw

19)

Hexagon head screw

24)

Spring washer

25)

Spring washer

DV 207

15-5

SECTION 44 – AXLES AND WHEELS – CHAPTER 15

4-10185A_A

15-6

DV 207

SERVICE MANUAL 1)

Hub

2)

Bearing

3)

Holder

5)

Driver

6)

Ring

7)

Ring

8)

Pipe

9)

Washer

10)

Fluid motor

11)

Gear

12)

Fluid motor

15)

Clutch

16)

Bearing

17)

Rubber mounting

20)

Nut

21)

Plate

23)

O-ring

24)

Seal

27)

Hexagon head screw

28)

Hexagon head screw

29)

Hexagon head screw

30)

Hexagon head screw

31)

Screw

32)

Socket head cap screw

33)

Hexagon head screw

34)

Hexagon head screw

35)

Nut

36)

Hexagon nut

38)

Spring washer

39)

Spring washer

40)

Washer

41)

Washer

44)

Connector

45)

Connector

46)

Plug

DV 207

15-7

SECTION 44 – AXLES AND WHEELS – CHAPTER 15

4-10221A

15-8

DV 207

SERVICE MANUAL 1)

Eccentric

2)

Eccentric

4)

Transfer weight

5)

Transfer weight

6)

Shaft

7)

Ring

8)

Ring

9)

Ring

10)

Feather key

13)

Bearing

15)

Nut

16)

Plate

17)

Feather key

DV 207

15-9

SECTION 44 – AXLES AND WHEELS – CHAPTER 15

"

15-10

DV 207

SERVICE MANUAL 1)

Holder

4)

Holder

5)

Holder

6)

Clip

7)

Clip

8)

Clip

12)

Connector

13)

Connector

14)

Connector

16)

Connector

18)

Connector

20)

Adjustable male stud run

21)

Manifold

27)

Hose

30)

Hose

32)

Hose

33)

Hose

34)

Hose

35)

Hose

36)

Hose

41)

Yoke

43)

O-ring

48)

Hexagon head screw

49)

Hexagon head screw

52)

Hexagon head screw

53)

Socket head cap screw

57)

Hexagon nut

59)

Hexagon nut

61)

Hexagon nut

65)

Spring washer

66)

Washer

68)

Spring washer

70)

Staple strip

71)

Staple strip

DV 207

15-11

SECTION 44 – AXLES AND WHEELS – CHAPTER 15 15.1. Removing hydromotor

the

vibration

The removal process is identical for the left-hand side of the front drum and the right-hand side of the rear drum.

NOTE: Position an oil pan under the hydromotor.

400A001 Mark and remove hoses one by one.

400A002 Blind the hydromotor hoses and outlets.

400A003 Detach the hoses and move them away.

400A004 15-12

DV 207

SERVICE MANUAL Remove the hydromotor mounting bolts.

NOTE: When reinstalling, clean the contact surfaces, use Loctite 262 to cement the bolts and torque tighten to 117 Nm (86 lb-ft).

400A005 We recommend replacement of the sealing ring.

400A006 Remove the plastic segment of the coupling.

Remove the coupling complete with locking ring.

NOTE: When reinstalling the locking ring, cement it with Loctite 577 and torque tighten to 10 Nm (7 lb-ft).

400A007 NOTE: Before performing any measurement, tap the vibrator into the bearing (13) in the hood on the opposite side.

1 15A

15B

Before installing the vibration hydromotor, measure the distance from the hub face (1) to the coupling (15A).

400A261 DV 207

15-13

SECTION 44 – AXLES AND WHEELS – CHAPTER 15 Adjust dimension X from the coupling face (15B) to the hydromotor face to ensure 3±0.2 mm (0.12±0.008 in) clearance between the hubs (15A) and (15B).

Degrease the hydromotor shaft end and coupling part (15B), apply Loctite 648 to the hydromotor shaft, heat coupling part (15B) to 110°C (230°F) and slip over the hydromotor shaft.

15A

15B

x

3±0,2

400A262

15.2. Removing hydromotor

the

travel

NOTE: Position an oil pan under the hydromotor.

400A008 Disconnect the revolution sensor pickup connector.

If required, adjust pickup as described in the section “11.5. Adjusting pulse sensors”.

400A010 15-14

DV 207

SERVICE MANUAL Mark the hoses.

400A009 Remove the hoses one by one. Blind the hydromotor hoses and outlets.

400A011 Remove the brake hose.

400A012 Remove the hydromotor fixing bolts.

NOTE: When reinstalling, use Loctite 262 to cement the bolts and torque tighten to 83 Nm (61 lb-ft).

400A013 DV 207

15-15

SECTION 44 – AXLES AND WHEELS – CHAPTER 15 15.3. Removing the auxiliary transmission Remove the travel hydromotor and disconnect the revolution sensor connector. Remove the auxiliary transmission fixing (refer to “15.2. Removing the travel hydromotor”).

Remove the hose clamp.

400A014 Attach the hose to the machine frame.

"

Suspend the right-hand yoke on the crane and remove the bolts for attachment to the frame and the crossmember one by one.

NOTE: When reinstalling, clean the contact surfaces, torque tighten the bolts to the frame (390 Nm (288 lbft)) and to the crossmember (200 Nm (148 lb-ft)).

" Remove the bolts securing the auxiliary transmission one by one.

NOTE: When reinstalling, clean the contact surfaces and torque tighten the bolts to 200 Nm (148 lb-ft).

400A017 15-16

DV 207

SERVICE MANUAL Move aside the yoke.

400A018 Remove the sprinkling hose.

400A019 Remove the bolts (29), leaving four bolts in place.

29

400A020 Install fixture no. [1]. Suspend the fixture on the crane and remove the remaining bolts (29).

NOTE: When reinstalling, clean the contact surfaces and torque tighten the bolts (29) to 83 Nm (61 lb-ft).

" DV 207

15-17

SECTION 44 – AXLES AND WHEELS – CHAPTER 15 Remove the oil filler and drainer, mark the position and remove the bolts used to attach the auxiliary transmission (11) to the carrier (5) and take off the carrier.

11

5

NOTE: When reinstalling, clean the contact surfaces and torque tighten the bolts (28) to 200 Nm (148 lb-ft).

28

400A022

15.4. Removing the front drum The removal procedure is identical for the front and rear drum.

Use a hand jack to lift the machine slightly on its lefthand side and right-hand side so that the drum has just slight contact with the ground. Position supports of sufficient load capacity underneath.

Mark drum position on both sides for reinstallation purposes.

Right-hand side NOTE: Position an oil pan under the hydromotor.

400A008

Disconnect the revolution sensor pickup connector.

400A010 15-18

DV 207

SERVICE MANUAL Mark the hoses.

400A009 Remove the hoses one by one. Blind the hydromotor hoses and outlets.

400A011 Remove the brake hose.

400A012 Remove the hydromotor mounting bolts.

NOTE: When reinstalling, clean the contact surfaces, use Loctite 262 to cement the bolts and torque tighten to 83 Nm (61 lb-ft).

400A013 DV 207

15-19

SECTION 44 – AXLES AND WHEELS – CHAPTER 15 Remove the hose clamp.

400A014 Attach the hoses to the machine frame.

"

Suspend the right-hand yoke on the crane and remove the bolts for attachment to the frame and the crossmember one by one.

NOTE: When reinstalling, clean the contact surfaces, torque tighten the bolts to the frame (390 Nm (288 lbft)) and to the crossmember (200 Nm (148 lb-ft)).

"

Remove the auxiliary transmission mounting bolts one by one.

NOTE: When reinstalling, clean the contact surfaces and torque tighten the bolts to 200 Nm (148 lb-ft).

400A017 15-20

DV 207

SERVICE MANUAL Move aside the yoke.

400A018 Remove the sprinkling hose.

400A019 Left-hand side Cut off the straps.

400A023 Remove the hose clamp.

400A024 DV 207

15-21

SECTION 44 – AXLES AND WHEELS – CHAPTER 15 Disconnect wiring connectors (X35, X36).

400A025 Suspend the crossmember on the crane, remove the mounting bolts and move it aside.

NOTE: When reinstalling, clean the contact surfaces and torque tighten the bolts to 200 Nm (148 lb-ft).

"

NOTE: Position an oil pan under the hydromotor.

400A001 Mark and remove the hoses one by one.

400A002 15-22

DV 207

SERVICE MANUAL Blind the hydromotor hoses and outlets.

400A003 Attach the hoses to the machine frame.

"

Secure the drum against any movement (fixture no.

[2]). Mark the position of the drum (1) on both sides.

2

2

1 400A028 Remove the bolts (17) of the steel sheet (4).

NOTE: When reinstalling, clean the contact surfaces and torque tighten the bolts (17) to 200 Nm (148 lb-ft).

17 4

400A029 DV 207

15-23

SECTION 44 – AXLES AND WHEELS – CHAPTER 15 Suspend the left-hand side yoke on the crane and remove the bolts for the machine frame one by one (shims between yoke and machine frame, use for the identical side).

Move aside the yoke.

NOTE: When reinstalling, clean the contact surfaces and torque tighten the bolts to 390 Nm (288 lb-ft).

400A030 Remove the vibration hydromotor mounting bolts.

NOTE: When reinstalling, clean the contact surfaces.

Use Loctite 262 to cement the bolts and torque tighten to 117 Nm (86 lb-ft). We recommend replacement of the sealing ring.

400A034 Roll the drum out of the machine and mark the position (2).

2

400A032

Remove left-hand side – vibration drive Secure the clamp (fixture no. 3) with a 2000 kg (4410 lb) load capacity. Suspend from the crane and position the drum erect with its right-hand side on the ground.

" 15-24

DV 207

SERVICE MANUAL Remove the bolts (18) securing the cover (3).

3

400A035

Push off the cover (3) evenly in forcing-off holes (3x) using bolts (18).

NOTE: When reinstalling the cover (3), clean the contact surfaces. We recommend replacement of the sealing ring.

When reinstalling, check the position of the cover (3) against the holes of bolts (18). Torque tighten the bolts (18) to 83 Nm (61 lb-ft).

18 3

400A036

Suspend the hub (1) including the cover (3) from the crane, lift it and move it aside.

1

3 400A037

DV 207

15-25

SECTION 44 – AXLES AND WHEELS – CHAPTER 15 Removing the slew Remove the bolts (27) of the cover (3).

27 3

400A038

Push off the bedding (2) evenly from the cover (3) in forcing-off holes (3x) using bolts (18).

NOTE: When reinstalling, clean the contact surfaces, use Loctite 262 to cement the bolts (27) and torque tighten to 200 Nm (148 lb-ft). We recommend replacement of the sealing ring.

3 400A039 Suspend the hub (1) including the bedding (2) from the crane, lift it and move it aside.

1 2 400A040 Push off the bearing (13) evenly using three M10 bolts.

400A041 15-26

DV 207

SERVICE MANUAL Release the locking sheet (21).

Use fixture no. 4 to remove the nut (20).

20 NOTE: When reinstalling the KM nut (20), apply lube grease MOLYKA-G and torque tighten to 25 Nm (18 lb-ft).

21

400A263 Push off the bedding (2) evenly from the hub (1) using two bolts.

Remove the oil seal (24) and ring (6); drive out the bearings (16).

NOTE: Use a new oil seal during reinstallation.

2 16 1 16 24 400A273

Removing the vibrating exciter Fit the M10 lifting lug. Lift the complete vibrating exciter and move it aside.

400A042 Left-hand side Remove the clutch part (15A).

NOTE: When reinstalling, degrease the shaft end (6), apply Loctite 648, heat the clutch part (15A) to 110°C (230°F) and slip over the shaft so the face of clutch part (15A) is aligned with shaft face.

6 DV 207

15A 400A044 15-27

SECTION 44 – AXLES AND WHEELS – CHAPTER 15 Release the locking sheet (16).

Use fixture no. [5] to remove the KM nut (15).

16

Use a puller to pull down the inner ring of the bearing (13) and ring (9).

15

Remove the rings (7).

NOTE: The vibrator, i.e. shaft (6) complete with eccentrics (1, 2), is a one-piece unit.

6

2

7

13 9 400A045

Right-hand side Release the locking sheet (16).

15 16

Use fixture no. [5] to remove the KM nut (15).

Use a puller to pull down the inner ring of the bearing (13) and ring (9).

Remove the rings (7).

NOTE: The vibrator, i.e. shaft (6) complete with eccentrics (1, 2), is a one-piece unit.

When reinstalling the cover assembly (drum is erected – aux. transmission for drive (11) down) tap the vibrator into the bearing in the cover (2), install cover (3) incl. bearing (13), screw the lifting lug into the thread and pull the vibrator to check axial clearance of 3 mm (0.12 in).

Removing right-hand side – travel drive

9

13 7

1

6 400A046

3

Secure the clamp (fixture no. [3]) with a 2000 kg (4410 lb) load capacity. Suspend from the crane and position the drum erect with its left-hand side on the ground.

400A047 Remove the screws (19) securing the cover (6).

NOTE: When reinstalling, clean the contact surfaces.

We recommend replacement of the sealing ring.

Check the position of the cover (6) against the screw holes (19). Use Loctite 262 to cement the screws (19) and torque tighten to 48 Nm (35 lb-ft).

19 6

400A048 15-28

DV 207

SERVICE MANUAL Remove the screws (17) securing the cover (2).

NOTE: When reinstalling, clean the contact surfaces.

We recommend replacement of the sealing ring.

Check the position of the cover (2) against the screw holes (17). Use Loctite 262 to cement the screws (17) and torque tighten to 83 Nm (61 lb-ft).

17 2

400A049 Push off the cover (2) evenly in forcing-off holes (3x) using screws (17).

17

2

400A050 Fit lifting lugs (3xM12). Suspend on a crane, lift and move aside.

400A051 Push off the bearing (13) evenly using three M10 screws.

400A052 DV 207

15-29

SECTION 44 – AXLES AND WHEELS – CHAPTER 15 15.5. Replacing the rubber mounting of the drum NOTE: The procedure is identical for the front and rear drum.

Left-hand side Lift the stirrup slightly to relieve the rubber mountings.

400A053 Slacken the screws (17) for the steel sheet (4) towards stirrup.

4

NOTE: When reinstalling, tighten the screws (17) to 200 Nm (148 lb-ft) torque.

17 400A054 Remove the bolts used to secure the rubber mountings to the steel sheet (4).

4

400A055 Remove the bolts used to secure the rubber mountings to the hub (1).

1

400A056 15-30

DV 207

SERVICE MANUAL Slacken the bolts of the second rubber mounting to relieve the force on the rubber mounting clamped between the hub and the steel sheet.

400A057 Release the rubber mounting.

NOTE: When reinstalling, torque tighten the rubber mounting bolts to 83 Nm (61 lb-ft).

400A058 Right-hand side Lift the stirrup slightly to relieve the rubber mountings.

400A059 Remove the bolts used to secure the rubber mountings to the carrier (5).

5

400A060 DV 207

15-31

SECTION 44 – AXLES AND WHEELS – CHAPTER 15 Remove the bolts used to secure the rubber mounting to the bracket.

400A061 Slacken the bolts of the second rubber mounting to relieve the force on the rubber mountings clamped between the carrier and the bracket.

400A062 Detach the rubber mountings.

NOTE: When reinstalling, torque tighten the rubber mounting bolts to 83 Nm (61 lb-ft).

400A063

15-32

DV 207

SERVICE MANUAL

SECTION 50 – CAB CLIMATE CONTROL 16. Removing the heater/cooling air fans

DV 207

16-1

SECTION 50 – CAB CLIMATE CONTROL – CHAPTER 16

16-2

DV 207

SERVICE MANUAL 1)

Plate

3

Plate

4)

Cover

5)

Clamping device

8)

Valve

9)

Pull rod

11)

Connector

12)

Connector

13)

Manifold

14)

End fitting

15)

End fitting

16)

Sleeve

17)

Cap

18)

Symbol

19)

Rubber profile

20)

Rubber profile

25)

Hose

26)

Hose

27)

Hose

28)

Hose

29)

Hose protection

32)

Hose protection

35)

Hose clamp

40)

Hexagon head screw

41)

Hexagon head screw

42)

Hexagon head screw

43)

Hexagon head screw

44)

Hexagon head screw

47)

Hexagon nut

50)

Washer

51)

Spring washer

52)

Spring washer

60)

Staple strip

DV 207

16-3

SECTION 50 – CAB CLIMATE CONTROL – CHAPTER 16 16.1. Removing the heater Bleed some of the coolant – approx. 6 l (1.6 US gal).

Disconnect the hoses.

401D209 Disconnect the heating unit.

401D210 Take it out.

401D211 Remove the heater hose (1) and screws (2).

With the heater removed, refill the coolant.

2 1

1 2

401D212 16-4

DV 207

SERVICE MANUAL Notes

DV 207

16-5

SECTION 50 – CAB CLIMATE CONTROL – CHAPTER 16

"

16-6

DV 207

SERVICE MANUAL 2)

Padding

106)

Screw head cover

3)

Cab

113)

Hexagon head screw

4)

Panel

116)

Oval head countersunk screw

5)

Cover

119)

Socket head cap screw

6)

Armrest

120)

Hexagon head screw

7)

Armrest

121)

Countersunk screw

13)

Cover

122)

Hexagon head screw

14)

Cover

123)

Hexagon head screw

16)

Holder

124)

Hexagon head screw

18)

Plate

129)

Plate screw

19)

Washer

130)

Screw

21)

Grille

131)

Nut

27)

Plate

133)

Nut

29)

Nut

134)

Nut

30)

Pull rod

135)

Washer

31)

Pull rod

137)

Washer

32)

Screw

138)

Washer

41)

Hose

139)

Washer

59)

Holder

140)

Washer

60)

Crank

142)

Spring washer

61)

Crank

152)

Cover

62)

Lever

153)

Cover

63)

Lever

154)

Holder

64)

Door lock

155)

Mirror

65)

Door lock

156)

Rubber profile

66)

Washer

157)

Socket head cap screw

67)

Washer

158)

Oval head countersunk screw

68)

Bolt

69)

Cover

70)

Wrench

74)

Fan

79)

Ventilation nozzle

80)

Armrest

81)

Grille

83)

Dummy plug

84)

Suspension

86)

Feedthrough

89)

Y branch

90)

Clutch

92)

Handle

96)

Spring

100)

Strut

103)

Grease nipple

104)

Dummy plug

105)

Plug

DV 207

16-7

SECTION 50 – CAB CLIMATE CONTROL – CHAPTER 16 16.2. Removing cooling air fans Bleed some of the coolant – approx. 6l (1.6 US gal).

Disconnect the hoses.

401D209 Disconnect the heating unit.

401D210 Take it out.

401D211 Disconnect the wiring connectors. Remove the cooling air fan mounting.

400A295 16-8

DV 207

SERVICE MANUAL Remove the rearview mirror.

400A163 Remove the front cover screws.

400A164 Disconnect the wiper motor connectors.

400A165 Remove the screws of the wiper motor mounting.

400A166 DV 207

16-9

SECTION 50 – CAB CLIMATE CONTROL – CHAPTER 16 Notes

16-10

DV 207

SERVICE MANUAL

SECTION 55 – ELECTRICAL SYSTEM 17. Electrical installation

DV 207

17-1

SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 17 17.1.

Fuses

Fuse box Contains F1 - F8 fuses.

F1 - 20 A

front, tail lights

F2 - 15 A

ceiling lights, light switch

F3 - 15 (30)A

direction indicators, horn, beacon, extra lights, light socket

F4 - 5 A

clusters

F5 - 10 A

electronics for travel, reversing horn

F6 - 15 A

sprinkling

F7 - 7.5 A

vibrations, CRAB (edge cutter)

F8

spare

400A267

Other fuses located in the machine With master switch F9

radio (as per car radio manufacturer)

400600 Underneath cab lighting cover F11 - 15 A

windshield sprayers

wipers

+

windshield

F12 - 15 A

cooling air fans

F13 - 5 A

control of cooling air fans + air conditioner

F14 - 10 A

air conditioner

400118

400119 17-2

DV 207

SERVICE MANUAL F16, F17 - 125A engine preheating F16

F17

400601 Cab fuse F15 - 30 A

cab wiring

NOTICE Replace fuses only with fuses of identical value!

400A268

DV 207

17-3

SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 17 17.2. Storage battery

Maintenance during operation

The maintenance-free storage battery is located in the rear frame of the machine.

A properly functioning charging system will keep the storage battery almost fully charged. The regulated voltage level moves within 13 - 14 V limits.

Charging

Recharge the battery with current from 0.1 of its total capacity up until the fully charged indicator comes on.

Measure the no-load voltage of the battery with a digital multimeter.

Data for checking the charge 100% charge means no-load voltage is over 12.6 V 70% charge means voltage is 12.40-12.54 V 50% charge means voltage is 12.24-12.40 V Deep discharge is below 12.18 V It is normal to charge a new storage battery via software-controlled charger according to IU, IUIA characteristics.

Indication of charge 100% charged storage battery (measured at current flow required) -

Voltage will reach its max. level. During charging, voltage will not change for the period of 2 hours.

The best conditions for battery operation and storage are frequent discharging and recharging along with 100% condition. Maintain the batteries at full charge condition over 12.5 V no-load voltage.

Keep storage batteries clean and well secured. Make sure the fixing device does not deform the storage battery block. Battery terminals must be properly tightened.

Aerosol of electrolyte forms sulfates on the surface of terminals’ metal parts. Clean up these sulfates. Protect cleaned metal parts with a thin layer of preservation vaseline or oil.

NOTICE Handle the storage batteries and electrolyte with adequate care. Wear gloves and safety glasses (face shield).

If skin comes into contact with electrolyte, flush immediately with water; use soap or baking soda to neutralize. When charging, oxygen and hydrogen are released from the electrolyte on the electrodes, forming and explosive mixture. It is therefore strictly forbidden to perform hot work in the vicinity of the storage battery. Even a spark generated when disconnecting or loosening a terminal with the charging circuit energized could cause an explosion.

When removing, disconnect the negative (–) pole cable first and then the positive (+) one.

NEVER disconnect the storage battery with the engine running.

When operating and handling storage batteries, always follow the safety procedures, recommendations and warning provided by the battery manufacturer.

17-4

DV 207

SERVICE MANUAL 17.3. Alternator

Informative machine

The alternator is used as an electric power supply.

This inspection is of an informative nature. Only an inspection with measurable load using an test bench can be considered binding.

There is a semiconductor voltage controller to maintain input voltage within a certain range at variable rpm, variable load and at variable ambient temperature.

inspection

of

alternator

on

the

Preconditions for proper operation are as follows:

Regulated voltage will alternate on B+ terminal.

-

Undamaged wiring

Cooling is provided via a cooling air fan, where direction of rotation has been identified.

-

Proper electrical connections on alternator, controller, storage battery terminals

The alternator must always operate with the storage battery connected – positive battery pole connected to the B+ terminal. NEVER disconnect the battery during operation.

-

Sufficient drive belt pull – permissible radial force acting on alternator shaft from belt pull along pulley axis is max 800 N.

Avoid any short circuits within the alternator circuit.

Disconnect alternator cables from the electrical system when performing any wiring repairs. When repairing wiring or performing welding, ALWAYS disconnect the alternator cables from the electrical system. When starting with an external auxiliary power supply, NEVER disconnect the power supply before the battery is connected. Do NOT start running the alternator with no load, i.e. with the cable disconnected from the B+ terminal and the D+ terminal connected.

Any failed alternator or controller may cause not only storage battery under-recharging but overcharging as well.

During normal workshop inspection of the entire power supply system (when no malfunction is expected), it is sufficient to check control voltage or how the indicator lamp reacts to increased rpm. With a voltmeter connected to the B+ terminal, the regulated voltage must move in the mean speed zone within 13 - 14 V range.

If the bulb of the recharging indicator lamp burns out, replace it immediately. No power will be supplied to the alternator if the recharging indicator lamp is defective.

When washing the engine compartment, prevent water and dirt from penetrating into the alternator via the vents.

NOTE: During welding work on the machine you must disconnect alternator – wires from B+ and D+ terminals – and electrical units or instruments with semiconductor elements. Disconnect the storage battery before repairing other electric equipment.

W A

B+ D+ B-

B-

V

REG.

401D285 DV 207

17-5

SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 17 TROUBLESHOOTING THE ALTERNATOR - CONTROLLER Inspecting the alternator-controller set using a test bench.

Remove the controller subassembly from the alternator complete with carbon brush holder and replace (reinstall) the subassembly with a controller that is known to be good.

Check regulated voltage on a test bench.

Inspecting an alternator with no controller – test bench.

• Remove the controller subsystem together with brush holder and secure a modified brush holder to the alternator. On the modified brush holder, there is one brush cable connected to frame. On the second cable of the brush, there is a wire soldered incl. a socket for connector that will be connected to D+ terminal and continue for approx. 20 cm length to enable short-term energizing from B+ terminal.

• Attach the alternator and connect it to a test bench with voltmeter, ammeter, load resistor, revolution counter and battery. Refer to the figure.

• Get the alternator moving at about 1500 rpm.

• Energize the alternator – attach the end of the free wire connected to the brushes and D+ terminal to the B+ terminal for 2-3 sec. If unable to energize, the alternator is defective.

• Check alternator properties.

If no alternator defect is found, troubleshooting of the controller is required.

Poor contact between the alternator frame and vehicle frame or an improper storage battery ground connection could also be the cause of a fault.

Voltage controller An integrated voltage controller is involved. The alternator excitation circuit is connected between the DF and D+ terminals of the controller. The controller itself is connected to a brush holder and 2 bolts are used to attach the entire subassembly to the alternator. Its interconnection is made through three soldered circuits (B-, DF, D+) and a cable (rope) terminated with socket 6,3 to be slipped onto the alternator’s D+ connector. The controller cannot be repaired.

LIST OF POSSIBLE DEFECTS Signs that the storage battery is not being recharged Defective controller

Replace controller

Defective rotor – short-circuited winding to Replace rotor Recharging indicator ground lamp ON while engine is Defective stator – ground short circuit Replace stator running Defective diode within block Replace defective diode Loose soldered connections on diode cables or Clean, re-solder stator outlets Defective indicator lamp

Replace bulb

Bad connection on D+ terminal or on battery Clean the connections, tighten Recharging indicator terminals lamp does not light up Defective rotor; winding broken Replace rotor after ignition is turned ON Carbon brush seizing in holder Release carbon brush, clean or replace if required Dirty rotor rings

Clean

Signs of battery overcharging Defective ground connection in charging system circuit

Clean grounding points, tighten: controller - alternator, battery – vehicle body, body – engine

Defective controller

Replace

Faulty auxiliary diode

Replace

17-6

DV 207

SERVICE MANUAL 17.4. Starter motor

Checking idling – on the machine

Operation and maintenance • For the starter motor to operate properly, it is essential to have an appropriate and fully charged storage battery.

• The starter motor is designed for short-term operation.

• Stop the start attempt once the engine starts – the starter motor pinion and bearing could otherwise be damaged.

• Make sure feeder cables have cable heads perfectly tightened, with no broken insulation.

• The starter motor frame forms part of the electric circuit. Keep contact surfaces on the engine metal clean and protect against corrosion.

• If the starter motor does not work, search for a disrupted cable between the storage batteries and starter motor, between the engine frame and starter motor or between the engine frame and batteries.

• Check the flywheel rim gear and pinion gear for wear and tear. When inspecting, lubricate with lube grease.

• During engine repair or once every 2 years, repair starter motor of the machine. Check the commutator, brushes, brush springs and switch contact surfaces.

Make sure brushes are seated with 3/4 of their surface on the commutator and are able to slide lightly. Make sure contact surfaces of the switch contacts are not burnt out and bear on each other with their full surface.

Test the starter motor in such a position where the pinion is not engaged with the gear rim even when shifted out. When starter motor circuit is turned ON, the pinion must shift out and start spinning. An unloaded starter motor may operate for max. ten seconds. Refer to the section “Informative inspection of starter motor” for a detail description of such inspection.

Starter motor troubleshooting Connect terminal “30” of the starter motor to a properly charged battery, connect an ammeter with long effective range of wiring measurement to the circuit.

Start (supply current to terminal “50”). The strength of current while running on no-load must not exceed 120 A (peak upon instantaneous deflection is not taken into account). The starter motor must run quietly. The pinion must smoothly shift out and return to its home position. With the pinion out, the pinion should not spin right on the front of the cap ring. Slowing down (after-run) of the starter motor after the sensor is disconnected from the power supply may last only eight minutes. Check the pressure and condition of carbon springs. Carbons must be seated on the collector with at least 2/3 of the surface and must be able to move within the chambers. The armature must have perceptible axial clearance of max 1.3 mm (0.05 in).

When pinion turns a bit in the direction of starter motor rotation, the starter motor overrunning clutch must slip slightly for a moment. If there is sufficient experience, the inspection with running on no-load is sufficient for workshop evaluation. However, we recommend testing on a test bench.

А V

50

30

401D286 DV 207

17-7

SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 17 Starter motor faults and their remedies Fault

Cause

Remedy

Broken wire to terminal “30” of the Repair wire switch Broken wire to terminal “50” of the Repair wire switch Defective ignition switch Starter motor does not rotate when Burnt contacts turned ON

Replace ignition switch Replace contacts and/or the entire cover (always together with bridging contacts)

Broken winding for starter motor Replace starter motor switch switch Short-circuited switch (poor pull, Replace starter motor switch runs hot) Switch armature seizes

Free, clean and apply oil

Shifting-out mechanism damaged

Replace, or repair if required

Pinion drags behind on shaft

Repair (sometimes shaft needs to be aligned)

Defective ignition switch

Replace ignition switch

Starter motor runs on no-load

Replace contacts (together with Starter motor does not switch OFF Caked starter motor switch contacts bridging contacts or and/or whole – remains engaged, disconnect switch) battery immediately (ground pole)!

Replace pinion bearing. Eliminate Jammed pinion on shaft sharp edges on shaft, clean (check for shaft untrue running) Starter motor does not shift out Flywheel rim damaged pinion for mesh

Repair and/or replace damaged rim (find out cause)

Disengaging spring broken

Replace spring

Pinion gear damaged

Replace pinion (find out cause)

Pinion mill flywheel Battery discharged Charge battery You can hear the starter motor Damaged overrunning clutch slips engages the pinion, but it does not Replace (casing broken) make the engine turn over Burnt starter motor switch contacts Replace

17-8

DV 207

SERVICE MANUAL

Fault

Cause

Remedy

Battery not charged sufficiently

Charge battery

Dirty and/or loose connections in Clean, tighten properly feed cables (contact resistances) Battery faults (starting normally Repair battery fault worsens gradually) Starter motor carbons damaged

Replace carbons (normally commutator repair required)

Clean with gasoline or alcohol.

When commutator is burnt and/or mica comes out in between plates (strong sparking during operation), Dirty and burnt and/or unsoldered disassemble starter motor and commutator machine a bit in the commutator.

Starter motor does not work reliably.

Mill out the insulation; polish the Low, inefficient performance commutator. If required, solder again and/or replace the armature.

Broken and/or heated up carbon Replace spring springs Armature short-circuit

Replace armature

Part of exciting coils is disconnected Replace relevant pair of coils (interrupted) Faulty starter motor switch (contact Replace ignition switch resistance) Broken exciting winding of stator at the cable to the starter motor switch Resolder at the cable point terminal Starter motor is loose at the flange

Tighten the screws

Armature loose (seized in bearings) Repair Loud starter motor operation Mechanical fault (miscellaneous)

Repair defect

Broken cover (max noise)

Repair/replace cover

Starter motor runs excessively hot, Eliminate short circuit or replace Short circuit within excitation circuit low power relevant pair of coils

DV 207

17-9

SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 17 17.5. Layout of wiring elements in the machine

A

S38

B

B1

C D

B5

M2, M3

B3

S8, S42

X37, X38

S10 B4 S12

S11 G2

kostra (ground) M1 Y1 S9

B5

S41, S40 M3 M2 B1

E

E11, E19 E3 E8

E1, E12 E6

X43

H3 C1 E5

E7 E4 E10, E18 G1

S38

Q1

Y10

Y11

S42 S8

B3

X35, X36

E2, E9

400A260 Description of the parts in individual figures as per the wiring diagram legend.

S28 S29

S30 S31 S23

S22

View A S15

V5 V6

V7 V8

S14 A5

400A260A 17-10

DV 207

SERVICE MANUAL View B Y15

Y16

Y12

Y13 Y3 Y14 S7

400A260B View C F16 K20

F17

K21

K1

400A260C View D

Y9

Y5

Y4

Y8

400A260D

View E

S40 S41

400A260E DV 207

17-11

SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 17 Notes

17-12

DV 207

SERVICE MANUAL

SECTION 55 - ELECTRICAL SYSTEM 18.

DV 207

Electrical system

18-1

SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 18 F9 G1 K20

F17

G

B

56b 56a

31

56b 56a

E6

X26:2

X5:26

X26:3

X5:27

X8:1

K3 85 87

Y S Z

X7:1 86 30

X8:2

H3

X27:1

X5:5

X31

E7

X5:36

15(30)A

K4

K5 85 30

5 10

17 87 86

86 87

30 85

K6

87 86

X8:3

E8

S3

X8:5

1 9

30 85

S2.5 O

X8:4

Rear headlights

X28:2

30

19

F3

S2.3 S2.4 B X7:4

C M MC

C1

Loud horn

15A

S2.2

X7:3

S1 15/54 50a

F2

S2.1 H X7:2

X5:25

E5

31

Front headlights

X5:4

0 12

X28:1

20A

S2

X61

E21

Vehicle make lighting

30 86

X5:32

F1 87 85

E4

X5:2

Rear lights

K2

X62:5

H1

E3

K1

X5:60

H2

X5:3

X3

X26:1

X5:35

E2

50

L IG X62:4

80A

F10

E1

Front contour lights

30

G2

125A

K21

R5

Engine preheating

M1

31

12V 100Ah

125A

M

R4

Engine preheating

Q1

F16

X26:4 X28:4

Left front direction indicator Left rear direction indicator

E9

X27:2

X5:7

E10

X29:2

X5:8

2 8

Right rear direction indicator Right front direction indicator

E11

X29:3

X5:9

3

E12

X27:3

X5:10

E13

Auxiliary headlights front

X6:4

X51

87 85

E14

S4

A1 CL

6 1 5 10

K7

31

30 86

X1

X52

E15

Auxiliary headlights rear

X49:2

X53

S6

X56:2

E17

Hazard warning beacon

X30

X54

5 10

X6:5

X56:1

E16

S5

1 9

1 9

X6:6

X55:1

5 10

X55:2 X49:6

Brake lights

X28:3

87

X5:12

8 18 19 11

X5:13

13

E19 P P P

S42

15

X5:15

16

X62:3

X5:16

17

X5:17

2 7 6 9 5

S12

Hydraulic oil overheating

X5:18

Air filter Engine lubrication

3 12

X9

X5:14 X62:6

30

14

Seat

Hydraulic filter

A2

P

S7 S8 S9 S10 S11 B1

15

87a

Instrument illumination Direction indicators Charging+ engine hours Direction indicators Neutral Brake

X9

Brake Hydraulic filter Air filter Engine lubrication Engine overheating Fuel gauge

A6

31

X5:11

ta

E18

Engine overheating

F4

20

Supply +12V

Fuel gauge Hydraulic oil level Hydraulic oil overheating Engine stop

5A

10

Ground

R3

1

Warning

75 R

Vibration

X5:19

B3

Water tank level

7 9 8 2

X5:20

S13 X63:1

X5:21

11 13 5 14

X62:2 X63:2 X62:7

Reversing horn

H5 X32:1

X32:2

X5:24

Air conditioner

Crab

Constant speed Smooth start-smooth stop

X12:2 black

blue

87a 86

87a

30

87 85

40 Smooth start

X65:2 white

B5

X5:44

X65:1 X5:43

A4/17

Front right drum speed

1(Brown)

Blue

B5

4(Black)

X5:43

17 Drum

speed

Seat

3(Blue)

Brake Travel forward Travel rearward

Y3

X5:38

41

Y4

X5:39

6

Y5

X5:40

7 Travel rearward

X5:41 X60

8

Brake

Vibration

A4

RS2323 RxD

Drum speed sensor

B4

X33:1

RS2323 Grd

15

X5:30

29

X5:42

16 26

(12V)

Travel

S20

1

5

S21

X15:1

S22

X17:1

S23

X17:2

X2 2 3 5 9

13 32

X11:6 X16:1

6 5

Engine speed Sprinkling

34

X11:7 X16:2

Speed

31

100R 1K X11:8 X14:3

A5

1

R1

Vibration Sprinkling

X15:2

21

X16:3

100R

R2 100R

X14:4

X5:46

X14:2

5

20

X11:9 X33:2

5

1

(12V)

5V 14 (5V) 1

27

12 X11:5

RS2323 TxD

S18

1

S19

5 X11:4 X13:2

Travel forward

X5:6 X5:29

2

Automat. vibration 4 X11:3 Smooth start - smooth stop

X5:44

K10/3

7

19

- smooth stop

brown

X11:2

V14

X13:1 X14:1

X5:45

30 86

speed Engine overload

Neutral

X5:45

K17

3 Constant

12V

18 X65:3

X12:4

2 X16:8

Hydraulic oil level

S38

85 X5:28 87 87a X5:37

brown

black

85 87

K10 X62:1

X12:1

S15

86 X12:6 30

28,42

Front drum speed - in the roller with one-piece drums

Y1

brown

S16

Fe PNP

X12:5

V11

S14

blue

K9

X62:8

F5 10A

30 86

X12:3

Engine stop

12 19 6

Engine overload

Sprinkling

K8

H4

17

X11:1 X16:7 1

X29:1

Water in fuel

Preheating

Fe PNP

87 85

20 1 10

X10

Float – water in fuel filter

A3

2

X10

1

Warning lights Engine stop Supply +12V Instrument Warning illumination Ground Water tank level

X11:10

1K

100R X14:5 X16:4

A

C

B

D E F

G H I

J

107641_1en

18-2

DV 207

SERVICE MANUAL 18.1. Wiring diagram DV207 A1 Clicker (course light interrupter)

R1 Sprinkling interval potentiometer

A2 Left-hand cluster

R2 Speed potentiometer

A3 Right-hand cluster

R3 Resistor

S30 Left-hand (yellow) button on right-hand travel controller – CRAB left or edge cutter up

A5 Travel controller

S1 Ignition switch

S30 Right-hand (yellow) button on right-hand travel controller – CRAB right or edge cutter down

A6 Time relay

S2 Combined switch

S32 Front wiper switch

A4 Travel electronics

R4, 5 Engine preheating

S33 Left rear wiper switch (option)

B3 Pressure sensor in water tank

S2.1 Switch for contour lights and headlights

B4 Engine speed sensor

S2.2 High beam/low beam switch

S35 Fan switch

B5 Drum speed sensor

S2.3 High beam flash switch

S36 Air conditioner switch (option)

C1 Interference filter

S2.4 Loud horn button

S37 Right rear wiper switch (option)

B1 Fuel level float

E1,2 Front contour lights

S2.5 Traffic indicator lights switch

S34 Sprayer button

E3,4 Rear lights

S3 Rear headlight switch

S38 Float in hydraulic oil tank

E5,6 Front headlights

S4 Hazard warning light switch

S39 CRAB reset button

E7,8 Rear headlights

S5 Auxiliary lights switch (option)

E9,10 Left direction indicators E11,12 Right direction indicators E13,14 Auxiliary headlights front (option) E15,16 Auxiliary headlights rear (option) E17 Hazard warning beacon (option) E18,19 Brake lights E20 Cab lighting E21 Vehicle make lighting (option)

S6 Hazard warning beacon switch (option)

S40,41 CRAB position switches S42 Hydraulic temperature switch

S7 Brake pressure switch

S43 Freezing thermostat – air conditioner (option)

S8 Switch for clogged hydraulic filter

S44 Air conditioner overpressure fuse (option)

S9 Switch for clogged air filter

S45 Scraper watering switch (option)

S10 Engine lubrication pressure switch S11 Engine overheating switch

X1 Mounting socket X2 Diagnostic socket X3-4 Connection terminals

S12 Hydraulic oil overheating switch

X5-64 Interface connectors

S13 Float – water in fuel filter

Y1 Engine stop solenoid

S14 Reversing horn switch

Y3 Brake valve

G1 Battery

S15 Neutral switch

Y4 Reverse drive valve

G2 Alternator

S16 Emergency brake button

Y5 Reverse drive valve

H1 Low beam indicator lamp

S18 Constant speed or engine overload switch

Y8 Vibration low amplitude valve

F1-17 Cut-out fuses

H2 High beam indicator lamp H3 Loud horn H4 Acoustic warning indicator

S19 Vibration automatics switch S20 Smooth start or smooth stop button

Y9 Vibration high amplitude valve Y10 Front drum vibration valve Y11 Rear drum vibration valve

H5 Reversing horn (option)

S21 Seat switch

Y12 CRAB left valve

K1 Contactor

S22 Vibration button (red) on the left-hand travel controller

Y13 CRAB right valve

S23 Vibration button (red) on the right-hand travel controller

Y15 Edge cutter up valve (option)

S24 Sprinkling button

Y16 Edge cutter down valve (option)

K2-19 Auxiliary relay K20 Preheating contactors K22 Auxiliary relay M1 Engine starter M2 Sprinkling motor M3 Sprinkling motor M4 Front wiper M5 Left rear wiper (option) M6 Right rear wiper (option) M7 Windshield washer M9,10,11 Fans Q1 Battery master switch DV 207

S25 Sprinkling pumps switch S26 Vibration amplitude switch S27 Front / both / rear vibration selector switch S28 Left-hand (yellow) button on left-hand travel controller – CRAB left

Y14 Relief valve

Y17 Air conditioner compressor clutch magnet (option) Y18 Solenoid valve of the edge cutter watering (option)

S29 Right-hand (yellow) button on left-hand travel controller – CRAB right 18-3

SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 18

X5:31

X35:1

86

85 30

7

K12

V2

M3

M

Sprinkling 2

15A

87

86

X5:33

A

X34:1 X34:2

B

V1

M2

M

Sprinkling 1

F6

X16:5 X11:11

5

1

C

D E F

I

G H CH

S24

X11:12 X16:6

K11 S25 5

1 85

87

30

X35:2

K22 85 87

1 9

86 30

Edge cutter sprinkling

Y18

X5:1

Vibration - low amplitude Vibration - high amplitude

Y8

X5:47

B4

B3

Y9

X5:48

A4

A3

D4

D3

C4

C3

S45

5 10

K13

Front drum vibration Rear drum vibration

86 87

S26

85 30

F7 7.5A

X11:13

S27

Y10

X5:49

B4

B3

Y11

X5:50

A4

A3

X5:22

1(brown)

X5:51 X12:8

X5:54

S41

X5:53

S39

X14:8 X14:10

6

2

X14:7 X12:7 X14:9 X12:9

S28

30A

X15:3

S29

Radio

X21:1 If the edge cutter is installed on the right-hand side of the roller, switch plug X20 to socket X21.

Buttons S30, S31 on the left control lever are used X21:2 for lifting the cutter.

Spare

X49:3

X17:3

X6:3

X12:16 X22:5

S31

X50

X12:15 X22:4

X5:59

S30

X49:5

X5:58

X20:1 X20:2

X49:1

Y15 Y16

V7 V8

Edge cutter up Edge cutter down

X12:14 X22:3

V5 V6

X5:57

Y14

Relief valve

X6:7

X6:1

X19:1 If the edge cutter is installed on the left-hand side of the roller, switch plug X18 to socket X19.

X19:2 Buttons S28, S29 on the left control lever are used for lifting the cutter.

X6:2

X18:2

F15

X18:1

X12:13 X22:2

X12:11

X12:12 X22:1

X5:56

87 85

X5:55

Y13

87

Y12

K18

K19 85

X5:23

Crabing left Crabing right

30 86

1

30

X12:10

5

86

X5:52

V13

1(brown)

4(black)

V12

Fe PNP

3(blue)

S40

PNP

CRAB position switch - right

3(blue) 2(white)

Fe

CRAB position switch - left

F8

E20

Cab lighting F11

X32:1 X32:4

15A

M4 X32:2

M

Front wiper

7 S32

5

X32:5

3

X32:3

M7 X64:1

M

X64:3

Windshield washer

7 2 8

1

M6

M

Right rear wiper (optional)

S34

X6:8

1

M5

M

Left rear wiper (optional)

1

X52 X6:9

7 2 8

5

1

S33

5 6

S37

5 6

X56:6

M

X58:1 1

Fan 1

3

M9 X58:2

M 3

Air conditioner

Y17

P

S44

S43

M10

X59:2

K15

F12

30

15A

86

S35 5

30

5A

1

86

2

1

M11 X48:2

9

2

F13

3

V9

M

X48:1 1

X56:5 87 85

3

K14

V10

X59:3

Fan 2 Fan 3

87 85

X58:3

X59:1 1

X56:4

2

S36

5 10

K16

X48:3 86

85

87

30

F14 10A

X4 X15:2 X17:2 X6:9

107641_2en

18-4

DV 207

SERVICE MANUAL Wiring diagram DV207 A1 Clicker (course light interrupter)

R1 Sprinkling interval potentiometer

A2 Left-hand cluster

R2 Speed potentiometer

A3 Right-hand cluster

R3 Resistor

S30 Left-hand (yellow) button on right-hand travel controller – CRAB left or edge cutter up

A5 Travel controller

S1 Ignition switch

S30 Right-hand (yellow) button on right-hand travel controller – CRAB right or edge cutter down

A6 Time relay

S2 Combined switch

S32 Front wiper switch

A4 Travel electronics

R4, 5 Engine preheating

S33 Left rear wiper switch (option)

B3 Pressure sensor in water tank

S2.1 Switch for contour lights and headlights

B4 Engine speed sensor

S2.2 High beam/low beam switch

S35 Fan switch

B5 Drum speed sensor

S2.3 High beam flash switch

S36 Air conditioner switch (option)

C1 Interference filter

S2.4 Loud horn button

S37 Right rear wiper switch (option)

B1 Fuel level float

E1,2 Front contour lights

S2.5 Traffic indicator lights switch

S34 Sprayer button

E3,4 Rear lights

S3 Rear headlight switch

S38 Float in hydraulic oil tank

E5,6 Front headlights

S4 Hazard warning light switch

S39 CRAB reset button

E7,8 Rear headlights

S5 Auxiliary lights switch (option)

E9,10 Left direction indicators E11,12 Right direction indicators E13,14 Auxiliary headlights front (option) E15,16 Auxiliary headlights rear (option) E17 Hazard warning beacon (option) E18,19 Brake lights E20 Cab lighting E21 Vehicle make lighting (option)

S6 Hazard warning beacon switch (option)

S40,41 CRAB position switches S42 Hydraulic temperature switch

S7 Brake pressure switch

S43 Freezing thermostat – air conditioner (option)

S8 Switch for clogged hydraulic filter

S44 Air conditioner overpressure fuse (option)

S9 Switch for clogged air filter

S45 Scraper watering switch (option)

S10 Engine lubrication pressure switch S11 Engine overheating switch

X1 Mounting socket X2 Diagnostic socket X3-4 Connection terminals

S12 Hydraulic oil overheating switch

X5-64 Interface connectors

S13 Float – water in fuel filter

Y1 Engine stop solenoid

S14 Reversing horn switch

Y3 Brake valve

G1 Battery

S15 Neutral switch

Y4 Reverse drive valve

G2 Alternator

S16 Emergency brake button

Y5 Reverse drive valve

H1 Low beam indicator lamp

S18 Constant speed or engine overload switch

Y8 Vibration low amplitude valve

F1-17 Cut-out fuses

H2 High beam indicator lamp H3 Loud horn H4 Acoustic warning indicator

S19 Vibration automatics switch S20 Smooth start or smooth stop button

Y9 Vibration high amplitude valve Y10 Front drum vibration valve Y11 Rear drum vibration valve

H5 Reversing horn (option)

S21 Seat switch

Y12 CRAB left valve

K1 Contactor

S22 Vibration button (red) on the left-hand travel controller

Y13 CRAB right valve

S23 Vibration button (red) on the right-hand travel controller

Y15 Edge cutter up valve (option)

S24 Sprinkling button

Y16 Edge cutter down valve (option)

K2-19 Auxiliary relay K20 Preheating contactors K22 Auxiliary relay M1 Engine starter M2 Sprinkling motor M3 Sprinkling motor M4 Front wiper M5 Left rear wiper (option) M6 Right rear wiper (option) M7 Windshield washer M9,10,11 Fans Q1 Battery master switch DV 207

S25 Sprinkling pumps switch S26 Vibration amplitude switch S27 Front / both / rear vibration selector switch S28 Left-hand (yellow) button on left-hand travel controller – CRAB left

Y14 Relief valve

Y17 Air conditioner compressor clutch magnet (option) Y18 Solenoid valve of the edge cutter watering (option)

S29 Right-hand (yellow) button on left-hand travel controller – CRAB right 18-5

SECTION 55 – ELECTRICAL SYSTEM – CHAPTER 18 Notes

18-6

DV 207

SERVICE MANUAL

SECTION 90 – CAB 19. Cab

DV 207

19-1

SECTION 90 – CAB – CHAPTER 19

4-04423A

19-2

DV 207

SERVICE MANUAL 1)

Housing

2)

Lever

3)

Lever

4)

Connecting rod

5)

Arm

6)

Lever

7)

Rocker

8)

Pull rod

9)

Ring

10)

Pin

11)

Bolt

12)

Brake

13)

Cover

14)

Cover

15)

Plate

16)

Pipe

17)

Lever

20)

Head piece

21)

Joint

22)

Angle transmitter

23)

Sensor

24)

Tension spring

25)

Hexagon head screw

26)

Hexagon head screw

27)

Hexagon head screw

28)

Socket head cap screw

29)

Hexagon head screw

30)

Set screw

31)

Socket head cap screw

32)

Oval head screw

33)

Hexagon nut

34)

Nut

35)

Nut

36)

Washer

37)

Washer

38)

Lock washer

39)

Lock washer

40)

Lock washer

42)

Circlip

43)

Hexagon nut

44)

Washer

45)

Washer

50)

Oval head screw

51)

Bush

52)

Spring pin

DV 207

19-3

SECTION 90 – CAB – CHAPTER 19 19.1. Idle and parking brake position sensor Replace the idle (neutral) and parking brake position sensor (23). Once replaced, adjust gap X between the rocker arm (7) and switch (23) to 1.5 mm (0.06 in).

23

X 7

401D226

19.2. Left-hand control panel, reversing horn sensor Remove the left-hand panel cover.

400A167 Replace the reversing horn switch (23), potentiometer for sprinkling interval control (47), travel controller position sensor (22) and STOP switch (43).

Once the reversing horn switch (23) has been replaced, adjust the gap between the arm (5) and switch (23) to 1.5 mm (0.06 in).

43 47 5 22 23

19-4

400A168 DV 207

SERVICE MANUAL NOTE: Replace the variable speed unit on the righthand control panel in the same way.

400A169

400A170

DV 207

19-5

SECTION 90 – CAB – CHAPTER 19

4-08034A

19-6

DV 207

SERVICE MANUAL 1)

Platform

46)

Spring washer

2)

Bracket

47)

Spring washer

3)

Base element

48)

Spring washer

4)

Locking device

49)

Washer

5)

Pedal

51)

Hook

6)

Pedal

52)

Cord

7)

Plate

8)

Door

9)

Cap

10)

Washer

11)

Plate

12)

Cover

13)

Plate

14)

Fuse

15)

Yoke

16)

Cap

17)

Plate

18)

Plate

19)

Insert

20)

Eccentric

21)

Diaphragm

22)

Diaphragm

23)

Ring

24)

Bush

25)

Spring

26)

Bearing

27)

Suspension

28)

Tongue lock

29)

Latch

30)

Straight pin

31)

Hexagon head screw

32)

Hexagon head screw

33)

Hexagon head screw

34)

Hexagon head screw

35)

Hexagon head screw

36)

Countersunk screw

37)

Countersunk screw

38)

Countersunk screw

39)

Hexagon nut

40)

Hexagon nut

41)

Nut

42)

Nut

43)

Washer

44)

Washer

45)

Washer

DV 207

19-7

SECTION 90 – CAB – CHAPTER 19 19.3. Seat platform Remove the four bolts securing the seat to the bed.

401D229 Remove the slew arrester pedals (5) on both sides.

5 401D230 Detach the seat from the slew.

401D231 Fold up to the side onto the cab floor.

401D232 19-8

DV 207

SERVICE MANUAL Remove the bearing pin nut (40).

40

400A265 Remove the spring (25), take off the arrester (4), take out the pin (20) and replace the bearing.

20 4

25

DV 207

400A266

19-9

SECTION 90 – CAB – CHAPTER 19

" 19-10

DV 207

SERVICE MANUAL 1)

Clip

6)

Flange

7)

Flange

8)

Connector

9)

Connector

10)

Connector

11)

Adjustable male stud

13)

T-socket

14)

Eye

15)

Flow control screw

18)

O-ring

24)

Yoke

30)

Hexagon nut

31)

Hexagon nut

35)

Washer

40)

Staple strip

50)

Hose

51)

Hose

52)

Hose

54)

Hose

55)

Hose

57)

Hose

58)

Hose

59)

Hose

60)

Hose

61)

Hose

62)

Hose

DV 207

19-11

SECTION 90 – CAB – CHAPTER 19 19.4. Power steering servo Remove the instrument board.

400A171 Unscrew and remove the steering wheel adjustment lever.

401D236 Pull down the dust cover from the steering column.

401D237 Disconnect connectors X 7, X 8.

401D238 19-12

DV 207

SERVICE MANUAL Remove the connection for the hydraulic power steering hoses.

401D239 Remove four screws securing the steering column to the power steering servo and remove the servo.

401D240

DV 207

19-13

SECTION 90 – CAB – CHAPTER 19

"

19-14

DV 207

SERVICE MANUAL 1)

Travel controllers

2)

Swivel

3)

Pillar

4)

Plate

5)

Plate

6)

Washer

7)

Operator seat

8)

Armrest

9)

Armrest

10)

Seat switch

11)

Box

12)

Steering wheel

13)

Cover

14)

Switch

15)

Power steering servo

16)

Hose

17)

Socket head cap screw

18)

Hexagon head screw

19)

Countersunk screw

20)

Hexagon head screw

21)

Hexagon head screw

22)

Hexagon nut

23)

Washer

24)

Spring washer

24)

Spring washer

25)

Spring washer

DV 207

19-15

SECTION 90 – CAB – CHAPTER 19 19.5. Seat switch Remove the three screws from underneath to remove the seat upholstery.

401D222 Take out the seat upholstery.

401D223 Fold up the seat.

401D224 Replace the seat switch after first drilling out 2 rivets.

401D225 19-16

DV 207

SERVICE MANUAL

INDEX

DV 207

20-1

INDEX

Index A

Transportation safety 2-12

U

Air conditioning 2-12 Alternator 17-5

Utility safety 2-13

B Battery 17-4 Battery safety 2-11

V Vibrator plate 15-12

W

C Washer fluid 6-5

Cab 19-1 Coolant 6-5

D Dimension diagram 6-8 Drum 15-1

E Electrical wiring elements 17-10 Engine oil 6-3 Entry and exit 2-12

F Fire and explosion prevention 2-10 Fluid/lubricant specifications 6-3 Fuel 6-4 Fuses 17-2

G General maintenance safety 2-10 General operating safety 2-4 General safety rules 2-3

H Hydraulic oil 6-5

L Lube grease 6-5

O Operator presence system 2-12 Operator protective structure 2-13

S Safety regulations 3-2 Safety sign location overview 2-4, 2-5 Safety signs 2-6 Specifications 6-6

T Technical data 6-6 Tightening of bolted joints 5-2 Tooling and equipment 7-2 20-2

DV 207

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Case¬is¬a¬registered¬trademark¬of¬CNH America LLC. Racine Wisconsin 53404 U.S.A.