Case DV209B Tier 3 Double Drum Compactor Operator's Manual - PDF DOWNLOAD

ORIGINAL INSTRUCTIONS

DV209B Tier 3 Double Drum Compactor PIN DDDD209BNGNT52033 and above

OPERATOR’S MANUAL

Part number 48038046 1st edition English August 2016

Contents 1 GENERAL INFORMATION Note to the owner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 CNH Industrial America LLC technical manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Intended use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Electro-Magnetic Compatibility (EMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Operator's manual storage on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Machine orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Machine components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

2 SAFETY INFORMATION Safety rules and signal word definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Ecology and the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Hand signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

3 CONTROLS AND INSTRUMENTS Access to operator's platform Cab access/exit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Operator's seat Operator seat adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Forward controls Steering column controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Left-hand side controls Left-hand armrest controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Right-hand side controls Right-hand armrest controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Rearward controls Rear panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Overhead controls Overhead panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Display Display unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Display screens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Ignition lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 Transport mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Climate controls Heating and air conditioning controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Cab features Interior component locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

4 OPERATING INSTRUCTIONS Commissioning the unit Before starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Starting the unit Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Stopping the unit Stopping the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Moving the unit Machine travel and reversing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Parking the unit Parking the machine and stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

5 TRANSPORT OPERATIONS Road transport Traveling on public roads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Shipping transport Machine transport (on a trailer). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Recovery transport Towing the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

6 WORKING OPERATIONS General information Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Compaction Machine travel and reversing including vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Sprinkling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Operating with vibration on compacted and hard materials . . . . . . . . . . . . . . . . . . . . . . . . 6-5

7 MAINTENANCE General information General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Power cut-off switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Window washer tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Hydraulic system care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Changing to Organic Acid Technology (OAT) coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Fluids, lubricants and capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Recommended engine oil for operating temperature ranges. . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 General specification - Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 General specification - Biodiesel fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 Assisted starting (jump-starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15 Lubrication and service schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

Maintenance planning Maintenance chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

Every 10 hours or daily Engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engines leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air filter dust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel tank level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controls and alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drum drive reducer gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air-conditioning compressor drive belt (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust system leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine fuel system pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator cooler fins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-20 7-21 7-22 7-22 7-22 7-23 7-24 7-25 7-26 7-28 7-28 7-29 7-29 7-29

First 200 hours Drum drive reducer gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

Every 250 hours or every 3 months Water filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31 Lubrication points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33

First 500 hours Vibration system oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35

Every 500 hours or every 6 months Engine accessory drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air intake and cooling hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air filter sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine coolant concentration level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air-conditioning refrigerant level (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab ventilation air filters (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine fuel filter and pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-36 7-37 7-39 7-40 7-41 7-41 7-42 7-42 7-43 7-46

Every 1000 hours or annually Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drum drive reducer gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vibration system oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rubber isolation mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water / Oil / Intercooler Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine and machine control modules/control units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air-conditioning compressor drive belt (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air-conditioning compressor mounting (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-49 7-50 7-52 7-54 7-54 7-55 7-57 7-58 7-59 7-59 7-60 7-61

Every 2000 hours or 2 years Hydraulic oil and filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62 Engine coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66

As required Bleeding the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water / Oil / Intercooler Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Scrapers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loose hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drain the water tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-69 7-69 7-70 7-71 7-72 7-73

Fuse and relay locations Fuse panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75

Storage Short term storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-77 Storage longer than 2 months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-78 Removing from storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79

8 SPECIFICATIONS General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Machine dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

9 ACCESSORIES Edge cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Infrared thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

1 - GENERAL INFORMATION

1 - GENERAL INFORMATION###_1_### Note to the owner Read this manual before you start the engine or operate the equipment. If you need more information, see your CASE CONSTRUCTION dealer.

This manual contains important information about the safe operation, adjustment and maintenance of your equipment.

This manual is divided into chapters as outlined in the table of contents. Refer to the index at the end of this manual for locating specific items about your equipment. The equipment conforms to current safety regulations.

Read this manual carefully, paying particular attention to the instructions concerning safety, operation and maintenance so as to avoid the risk of injury while operating or servicing the equipment. The equipment has been designed and manufactured according to the strictest quality standards. However, the risk of accidents can never be completely excluded. That is why it is essential to observe elementary safety rules and precautions.

DO NOT operate or permit anyone to operate or service this equipment until you or the other persons have read and understand the safety, operation and maintenance instructions in this manual. Use only trained operators who have demonstrated the ability to operate and service this equipment correctly and safely.

The information in this manual is provided on the basis of information that was available at the time that the manual was written. Settings, procedures, part numbers, software and other items can change. These changes can affect the service that is given to the equipment. Ensure that you have the complete and most current information from your dealer before you start any equipment operation.

The Operator's Manual is to be stored in the manual compartment equipped on this equipment. Make sure this manual is complete and in good condition. Consult your dealer to obtain additional manuals or manuals in other languages.

Your CASE CONSTRUCTION Dealer is available for any further information. They will also provide any after-sales service you may need, to include genuine CASE CONSTRUCTION spare parts, your guarantee of quality and match.

CASE CONSTRUCTION customer assistance is also available, go to www.casece.com.

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1 - GENERAL INFORMATION

CNH Industrial America LLC technical manuals Manuals are available from your dealer for your machine.

Your dealer can expedite your order for operator manuals.

All data given in this manual is subject to production variations.

Always give the machine name, Product Identification Number (PIN) of your machine so your dealer can provide the correct manuals for your machine.

NOTICE: Operating and service messages displayed on the electronic operating panel may vary from what the manual shows. If this occurs, heed the latest instructions on the electronic operating panel.

The company is continually striving to improve its products and therefore reserves the right to make improvements and changes when it becomes practical and possible to do so, without incurring any obligation to make changes or additions to the equipment sold previously.

Dimensions and weights are approximate only and the illustrations do not necessarily show the machine in standard condition. For exact information about any particular machine, please consult your dealer.

Manual scope and required training level This manual provides information on the intended use of your vibratory roller under the conditions foreseen by the manufacturer during normal operation, routine service and maintenance and periodic service and maintenance.

Normal operation is use of the vibratory roller for the purpose intended by the manufacturer by an owner/operator who is familiar with the unit, and who is complying with the information on operation and safe practices, provided in this manual and by the decals on the vibratory roller.

Normal operation includes such actions as preparing the unit for storage and removing the unit from storage, raising and lowering components into or out of work position, adjusting settings for specific field settings, etc.

Routine service and maintenance are those actions which must be performed daily to maintain proper vibratory roller function by an owner/operator who is familiar with vibratory roller characteristics, and who is complying with the information on routine service and safe practices in this manual and in the decals on the unit.

Routine service and maintenance includes such actions as fueling, cleaning, washing, topping off fluid levels, greasing, and replacing consumable articles such as lamp bulbs.

Periodic service and maintenance are those actions which must be performed at regularly defined intervals to

maintain proper vibratory roller function by an owner/operator who is familiar with vibratory roller characteristics, and who is complying with the information on periodic service and safe practices in this manual and in the decals on the unit.

Periodic service and maintenance includes such actions as checking, cleaning and changing air filters, changing engine oil and filters, changing hydraulic oil and filters, changing wheel hub fluids, changing coolant, etc.

Some actions in the periodic service and maintenance chart are beyond the knowledge and skills of the owner/ operator: for example, engine valve adjustment, fuel injector nozzles. For these actions, the manual instructs the owner/operator to have the action performed by their authorized dealer.

This manual does not contain all the information related to periodical service and maintenance, converting and repairs to be carried out by professional service personnel.

These actions require special facilities, technical skills, and/or tools which are not supplied with the machine.

Converting is changing the vibratory roller configuration for a specific condition and requires rebuilding or adding components to the vehicle. Repairing is the disassembly and assembly of the vibratory roller to restore proper operation after a component failure or degradation of performance.

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1 - GENERAL INFORMATION

Intended use The DV209B compactor has been designed to perform medium and large-sized compaction works in transport construction (roads and motorways, airfields) and building construction (industrial zones, etc.).

DV209B rollers are suitable for compacting the asphalt mixtures up to a layer thickness (after compaction) of 150 mm (5.9 in), hydraulically consolidated mixtures up to a layer thickness of 220 mm (8.7 in), mixed soils up to a layer thickness of 320 mm (12.6 in) and sand and gravel materials up to a layer thickness of 420 mm (16.5 in).

NOTICE: The rollers are not suitable for the compaction of rockfill, loam and clay materials.

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1

If you use this compactor for duties involving the use of attachments, accessories, or special tools, consult your dealer to make sure that the adaptations or modifications carried out are in conformity with the compactor’s technical specifications and with current regulations on safety.

Any modifications or adaptations which are not approved by the manufacturer may invalidate the compactor’s original conformity with safety requirements.

This compactor has been built with the most advanced technology and in accordance with recognized safety rules.

Illustrations in this manual may show protective shielding open or removed to better illustrate a particular feature or adjustment.

Replace all shields before operating the machine.

Failure to comply will result in death or serious injury.

The compactor must be used according to its intended use, respecting the safety and precautionary rules and strictly following the operating instructions. Any functional disorders, especially those affecting the safety of the compactor, should therefore be rectified immediately.

D0118A

CAUTION

WARNING

Equipment failure could cause accident or injury!

Tampering with or changing the setting of any hydraulic system valve is strictly forbidden.

Failure to comply could result in minor or moderate injury.

Avoid injury!

Using the machine for purposes other than or beyond the intended use is not allowed; for example: - for the transportation of persons, - as a working platform, - for pulling attached loads, - for pulling or transporting loads without the intended working equipment.

Failure to comply could result in death or serious injury.

C0160A

The current operator’s manual is the user’s guide for correct run-in, use and maintenance of the compactor.

Carefully read this operator’s manual and store it in the cab for quick location and reference.

W1142B

The manufacturer/supplier cannot be held responsible for any damage resulting from unintended use. The risk involved in such misuse lies entirely with the user.

DANGER

Instructions concerning safety, operation and maintenance provided in this manual have been developed to permit safe service and operation of this compactor.

In the event of queries or suggestions relevant to your compactor do not hesitate to address to your dealer.

Dealers have qualified and trained personnel at disposal as well as original spares, means and equipment suitable to carry out all necessary maintenance.

Do not use this compactor for any applications or purposes other than those described in this manual. If you

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1 - GENERAL INFORMATION

use this compactor for duties involving the use of attachments, accessories, or special tools, consult your dealer to make sure that the adaptations or modifications carried out are in conformity with the compactor’s technical specifications and with current regulations on safety.

Any modifications or adaptations which are not approved by the manufacturer may invalidate the compactor’s original conformity with safety requirements.

ATTENTION: The engine and fuel system on your machine are designed and built to government emissions standards. Tampering by dealers, customers, operators and users is strictly prohibited by law. Failure to comply with this prohibition could result in government fines, rework charges, invalid warranty, legal action and possible confiscation of the machine until rework to original condition is completed. Engine service and/or repairs must be carried out by a certified technician only.

Before entrusting this compactor to an operator, make sure that: • The operator is qualified to operate the compactor correctly and safely.

Your dealer is at your disposal for any further information you may need.

Spare parts The “non-genuine” spare parts have not been checked and authorized by the manufacturer. The assembly and/or use of such products may have negative effects on the compactor design features and could impair its operation safety. The manufacturer is not liable for any damage caused by “non-genuine” spare parts or accessories.

NOTE: Each compactor is supplied complete with a copy of this manual. Descriptions and illustrations provided herein are not binding. The manufacturer, provided that the basic characteristics of compactor types described and shown in this manual remain the same, reserves the right to change components, parts and accessories supplied without any commitment to timely update this publication, and this any time it deems it convenient for improvement purposes or due to commercial or manufacturing requirements. For exact information, please consult your dealer or contact the manufacturer’s branch offices, who remain at your disposal for further help.

• The operator has read and fully understood the instructions given in this manual.

Consult your dealer to obtain extra manuals or manuals in other languages.

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Electro-Magnetic Compatibility (EMC) Interference may arise as a result of add‐on equipment that may not necessarily meet the required standards. As such interference can result in serious malfunction of the unit and/or create unsafe situations, you must observe the following: • The maximum power of emission equipment (radio, telephones, etc.) must not exceed the limits imposed by the national authorities of the country where you use the machine • The electro‐magnetic field generated by the add‐on system should not exceed 24 V/m at any time and at any location in the proximity of electronic components • The add‐on equipment must not interfere with the functioning of the on board electronics Failure to comply with these rules will render the CASE CONSTRUCTION warranty null and void.

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Product identification When ordering parts, requesting information or assistance, always give your Dealer the model and Product Identification Number (PIN) of your machine and component concerned.

Machine Product identification plate (1) provides the following information: 1. Type / Model 2. Product Identification Number (PIN) The Machines PIN plate is located on the front right-hand frame just behind the roller.

The Product Identification Number (PIN) (2) is also stamped into the frame just below the PIN plate.

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1

RAIL14COM0348BA

2

RAIL16COM0130AA

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Engine Engine identification plate is in the right-hand engine compartment.

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Roll Over Protective Structure (ROPS) ROPS identification plate is located on the protective structure inside the cab

RAIL14COM0260AA

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1 - GENERAL INFORMATION

Operator's manual storage on the machine Keep the Operator's Manual in the storage compartment provided on the rear of the operator’s seat. The Operator's Manual must be available for use by all operators.

SS12C079

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1 - GENERAL INFORMATION

Machine orientation The terms “right”, “left”, “front” and “rear”, when used in this manual, indicate the sides of the machine as seen from the operator’s seat.

RAIL14COM0303FA

1.

2.

Front side Rear side

3.

4.

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1

Left side Right side

1 - GENERAL INFORMATION

Machine components

RAIL14COM0271HC

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1 - GENERAL INFORMATION

1.

2.

3.

4.

Front frame Rear frame Front drum Rear drum

12.

13.

14.

15.

5.

6.

7.

8.

9.

10.

11.

Engine Hydrostatic pump for travel (roll) Hydrostatic pump for vibration of front drum Hydrostatic pump vibration of rear drum Travel hydrostatic motor Vibration hydrostatic motor Steering joint

16.

17.

18.

19.

20.

21.

22.

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Hydraulics tank Fuel tank Sprinkling tank Cab with integrated Roll Over Protective Structure (ROPS) frame Driver’s control stand Batteries Combined cooler Air filter Exhaust pipe Sprinkling jets Drum scrapers

1 - GENERAL INFORMATION

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2 - SAFETY INFORMATION

2 - SAFETY INFORMATION###_2_### Safety rules and signal word definitions Personal safety 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 death or injury.

Throughout this manual you will find the signal words DANGER, WARNING, and CAUTION followed by special instructions. These precautions are intended for the personal safety of you and those working with you.

Read and understand all the safety messages in this manual before you operate or service the machine.

DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.

WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT IN DEATH OR SERIOUS INJURY. Machine safety NOTICE: Notice indicates a situation that, if not avoided, could result in machine or property damage.

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.

Information 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.

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Safety rules General safety rules Use caution when you operate the machine on slopes.

Raised equipment, full tanks and other loads will change the center of gravity of the machine. The machine can tip or roll over when near ditches and embankments or uneven surfaces.

Wear protective equipment when appropriate.

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

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

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

Always close access doors or panels before you operate the machine.

When digging or using ground-engaging attachments, be aware of buried cables. Contact local utilities to determine the locations of services.

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

Pay attention to overhead power lines and hanging obstacles. High voltage lines may require significant clearance for safety.

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.

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

Raised equipment and/or loads can fall unexpectedly and crush persons underneath. Never allow anyone to enter the area underneath raised equipment during operation.

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

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

• Stop the engine, remove the key, and relieve the pressure before you connect or disconnect fluid lines.

• Make sure that all components are in good condition.

Tighten all connections before you start the engine or pressurize the system.

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

• Continuous long term contact with hydraulic fluid may cause skin cancer. Avoid long term contact and wash the skin promptly with soap and water.

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

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

Before you start the machine, be sure that all controls are in neutral or park lock position.

Start the engine only from the operator’s seat. If you bypass the safety start switch, the engine can start with the transmission in gear. Do not connect or short across terminals on the starter solenoid. Attach jumper cables as described in the manual. Starting in gear may cause death or serious injury.

Operate controls only when seated in the operator’s seat, except for those controls expressly intended for use from other locations.

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2 - SAFETY INFORMATION

Before you leave the machine:

1. Bring the engine to low idle speed.

1. Park the machine on a firm, level surface.

2. Disengage all drive systems.

2. Put all controls in neutral or park lock position.

3.

3. Engage the parking brake. Use wheel chocks if required.

WARNING Some components may continue to run down after you disengage drive systems.

Make sure all drive systems are fully disengaged.

Failure to comply could result in death or serious injury.

4. Lower all hydraulic equipment — Implements, header, etc.

5. Turn off the engine and remove the key.

W0113A

When, due to exceptional circumstances, you would decide to keep the engine running after you leave the operator’s station, then you must follow these precautions:

Shift the transmission into neutral.

4. Apply the parking brake.

General maintenance safety Keep the area used for servicing the machine clean and dry. Clean up spilled fluids.

Stop the engine, remove the key, and relieve pressure before you connect or disconnect fluid lines.

Service the machine on a firm, level surface.

Stop the engine and remove the key before you connect or disconnect electrical connections.

Install guards and shields after you service the machine.

Close all access doors and install all panels after servicing 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.

Scalding can result from incorrect removal of coolant caps. Cooling systems operate under pressure. Hot coolant can spray out if you remove a cap while the system is hot. Allow the system to cool before you remove the cap. When you remove the cap, turn it slowly to allow pressure to escape before you completely remove the cap.

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

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

Unsupported hydraulic cylinders can lose pressure and drop the equipment, causing a crushing hazard. Do not leave equipment in a raised position while parked or during service, unless the equipment is securely supported.

The engine, transmission, exhaust components, and hydraulic lines may become hot during operation. Take care when you service such components. Allow surfaces to cool before you handle or disconnect hot components.

Wear protective equipment when appropriate.

Jack or lift the machine only at jack or lift points indicated in this manual.

Incorrect towing procedures can cause accidents. When you tow a disabled machine follow the procedure in this manual. Use only rigid tow bars.

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

Driving on public roads and general transportation safety

Use appropriate lighting to meet local regulations.

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

Make sure that the brake pedal latch is engaged. You must lock brake pedals together for road travel.

Travel speed should be such that you maintain complete control and machine stability at all times.

Use safety chains for trailed equipment when safety chains are provided with machine or equipment.

Slow down and signal before turning.

Comply with local laws and regulations.

Pull over to allow faster traffic to pass.

Lift implements and attachments high enough above ground to prevent accidental contact with road.

Follow correct towing procedure for equipment with or without brakes.

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2 - SAFETY INFORMATION

Fire and explosion prevention Fuel or oil that is leaked or spilled on hot surfaces or electrical components can cause a fire.

Crop materials, trash, debris, bird nests, or flammable material can ignite on hot surfaces.

belts, gears, cleaning fans, etc. More frequent cleaning of your machine may be necessary depending on the operating environment and conditions.

Always have a fire extinguisher on or near the machine.

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

Make sure that the fire extinguisher(s) is maintained and serviced according to the manufacturer’s instructions.

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

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 the engine, transmission, exhaust, battery, etc. More frequent cleaning of your machine may be necessary depending on the operating environment and conditions.

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

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

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

Do not expose the machine to flames, burning brush, or explosives.

General battery safety Always wear eye protection when you work with batteries.

Follow the manufacturer’s instructions when you store and handle batteries.

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

Ventilate the area when you charge a battery or use a battery in an enclosed area.

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

When you weld on the machine, disconnect both terminals of the battery.

Do not weld, grind, or smoke near a battery.

When you use auxiliary batteries or connect jumper cables to start the engine, use the procedure shown in the operator’s manual. Do not short across terminals.

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

This is a California Proposition 65 warning.

Battery acid causes burns. Batteries contain sulfuric acid.

Avoid contact with skin, eyes, or 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.

Operator presence system Your machine is equipped with an operator presence system to prevent the use of some features while the operator is not in the operator’s seat.

Never disconnect or bypass the operator presence system.

If the operator presence system is inoperable, then it must be repaired.

Reflectors and warning lights You must use flashing amber warning lights when you operate equipment on public roads.

Seat belts Seat belts must be worn at all times.

• Keep seat belts in good condition.

Seat belt inspection and maintenance:

• Keep sharp edges and items than can cause damage away from the belts.

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2 - SAFETY INFORMATION

• Periodically check belts, buckles, retractors, tethers, slack take-up system, and mounting bolts for damage and wear.

• Replace all parts that have damage or wear.

• If the belt is attached to the seat, make sure that the seat or seat brackets are mounted securely.

• Keep seat belts clean and dry.

• Clean belts only with soap solution and warm water.

• Replace belts that have cuts that can make the belt weak.

• Do not use bleach or dye on the belts because this can make the belts weak.

• Check that bolts are tight on the seat bracket or mounting.

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2 - SAFETY INFORMATION

Operator protective structure Your machine is equipped with an operator protective structure, such as: a Roll Over Protective Structure (ROPS), Falling Objects Protective Structure (FOPS), or a cab with a ROPS. A ROPS may be a can 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.

After an accident, fire, tip over, or roll over, the following MUST be performed by a qualified technician before returning the machine to field or job-site operations:

The protective structure is a special safety component of your machine.

• All damaged parts MUST BE REPLACED.

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

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 your dealer for protective structure inspection and replacement.

• The protective structure MUST BE REPLACED. • The mounting or suspension for the protective structure, operator’s seat and suspension, seat belts and mounting components, and wiring within the operator’s protective system MUST be carefully inspected for damage.

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 OVER, ROLL OVER, COLLISION, OR ACCIDENT. 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.

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.

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.

Only trained service technicians can service, repair, or recharge the air-conditioning system.

Personal Protective Equipment (PPE) Wear Personal Protective Equipment (PPE) such as hard hat, eye protection, heavy gloves, hearing protection, protective clothing, etc.

Do Not Operate tag Before you start servicing the machine, attach a ‘Do Not Operate’ warning tag to the machine in an area that will be visible.

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 within a product, safe handling and storage procedures, first aid measures, and

procedures to take in the event of a spill or accidental release. MSDS are available from your dealer.

Before you service 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, and on manufacturer containers, as well as the information in this manual, when you service the machine.

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2 - SAFETY INFORMATION

Dispose of all fluids, filters, and containers in an environmentally safe manner according to 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 or children or other unauthorized persons.

Applied chemicals require additional precautions. Obtain complete information from the manufacturer or distributor of the chemicals before you use them.

Utility safety When digging or using ground-engaging equipment, be aware of buried cables and other services. Contact your local utilities or authorities, as appropriate, to determine the locations of services.

Make sure that the machine has sufficient clearance to pass in all directions. Pay special attention to overhead power lines and hanging obstacles. High voltage lines may require significant clearance for safety. Contact local authorities or utilities to obtain safe clearance distances from high voltage power lines.

Retract raised or extended components, if necessary.

Remove or lower radio antennas or other accessories.

Should a contact between the machine and an electric

power source occur, the following precautions must be taken: • Stop the machine movement immediately.

• Apply the parking brake, stop the engine, and remove the key.

• Check if you can safely leave the cab or your actual position without contact with electrical wires. If not, stay in your position and call for help. If you can leave your position without touching lines, jump clear of the machine to make sure that you do not make contact with the ground and the machine at the same time.

• Do not permit anyone to touch the machine until power has been shut off to the power lines.

Electrical storm safety Do not operate machine during an electrical storm.

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

If an electrical storm 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.

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

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

Do not jump off of the machine.

Never mount or dismount from a moving machine.

Make sure that steps, ladders, and platforms remain clean and clear of debris and foreign substances. Injury may result from slippery surfaces.

Do not use the steering wheel or other controls or accessories as handholds when you enter or exit the cab or operator’s platform.

Face the machine when you mount and dismount the machine.

Working at heights When the normal use and maintenance of the machine requires you to work at heights:

• Do not stand on surfaces that are not designated as steps or platforms.

• Correctly use installed steps, ladders, and railings.

Do not use the machine as a lift, ladder, or platform for working at heights.

• Never use ladders, steps, or railings while the machine is moving.

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2 - SAFETY INFORMATION

Ecology and the environment Soil, air, and water quality is important for all industries and life in general. When legislation does not yet rule the treatment of some of the substances that advanced technology requires, sound judgment should govern the use and disposal of products of a chemical and petrochemical nature.

Familiarize yourself with the relative legislation applicable to your country, and make sure that you understand this legislation. Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, anti-freeze, cleaning agents, etc., with regard to the effect of these substances on man and nature and how to safely store, use, and dispose of these substances. Your CASE CONSTRUCTION dealer can also provide assistance.

Battery recycling Batteries and electric accumulators contain several substances that can have a harmful effect on the environment if the batteries are not properly recycled after use.

Improper disposal of batteries can contaminate the soil, groundwater, and waterways. CASE CONSTRUCTION strongly recommends that you return all used batteries to a CASE CONSTRUCTION dealer, who will dispose of the used batteries or recycle the used batteries properly. In some countries, this is a legal requirement.

Helpful hints • Avoid the use of cans or other inappropriate pressurized fuel delivery systems to fill tanks. Such delivery systems may cause considerable spillage.

• In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of these products contain substances that may be harmful to your health.

• Modern oils contain additives. Do not burn contaminated fuels and or waste oils in ordinary heating systems.

• Avoid spillage when you drain fluids such as used engine coolant mixtures, engine oil, hydraulic fluid, brake fluid, etc. Do not mix drained brake fluids or fuels with lubricants. Store all drained fluids safely until you can dispose of the fluids in a proper way that complies with all local legislation and available resources.

• Do not allow coolant mixtures to get into the soil. Collect and dispose of coolant mixtures properly.

• Do not open the air-conditioning system yourself. It contains gases that should not be released into the atmosphere. Your CASE CONSTRUCTION dealer or air-conditioning specialist has a special extractor for this purpose and can recharge the system properly.

• Repair any leaks or defects in the engine cooling system or hydraulic system immediately.

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1

Mandatory battery recycling NOTE: The following requirements are mandatory in Brazil.

Batteries are made of lead plates and a sulfuric acid solution. Because batteries contain heavy metals such as lead, CONAMA Resolution 401/2008 requires you to return all used batteries to the battery dealer when you replace any batteries. Do not dispose of batteries in your household garbage.

Points of sale are obliged to: • Accept the return of your used batteries • Store the returned batteries in a suitable location • Send the returned batteries to the battery manufacturer for recycling

• Do not increase the pressure in a pressurized circuit as this may lead to a component failure.

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2 - SAFETY INFORMATION

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

Start the engine

LEEN11T0005AA

1

LEEN11T0006AA

2

LEEN11T0007AA

3

Stop the engine

Come to me Wave hands back and forth (palms inward).

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Move away from me Wave hands back and forth (palms outward).

LEEN11T0008AA

4

LEEN11T0009AA

5

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6

LEEN12T0534AA

7

Go this far

All stop and hold

Stop Move one hand back and forth.

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2 - SAFETY INFORMATION

Emergency stop Move both hands back and forth.

LEEN11T0012AA

8

LEEN11T0017AA

9

Turn machine left To stop movement, stop moving hand and make a fist.

Turn machine right To stop movement, stop moving hand and make a fist.

LEEN11T0018AA

2-11

10

2 - SAFETY INFORMATION

Safety signs WARNING Avoid injury!

Make sure safety signs are legible. Clean safety signs regularly. Replace all damaged, missing, painted over, or illegible safety signs. See your dealer for replacement safety signs. If a safety sign is on a part that is replaced, make sure the new part has a safety sign.

Failure to comply could result in death or serious injury.

W0168A

The following safety signs are on your machine as a guide for your safety and for the safety of those working with you.

Walk around the machine and note the content and the location of all safety signs before you operate your machine.

Keep all safety signs clean and legible. Clean safety signs with a soft cloth, water, and gentle detergent. NOTICE: Do not use solvent, gasoline, or other harsh chemicals. Solvents, gasoline, and other harsh chemicals may damage or remove safety signs.

Replace all safety signs that are damaged, missing, painted over, or illegible. If a safety sign is on a part you or your dealer replaces, make sure that you or your dealer install the safety sign on the new part. See your dealer for replacement safety signs.

Safety signs that display the “Read operator’s manual” symbol direct you to the operator’s manual for further information regarding maintenance, adjustments, or procedures for particular areas of the machine. When a safety sign displays this symbol, consult the appropriate page of the operator’s manual.

Safety signs that display the “Read service manual” symbol direct you to the service manual. If you doubt your ability to perform service operations, contact your dealer.

2-12

2 - SAFETY INFORMATION

RAIL16COM0108HA

2-13

1

2 - SAFETY INFORMATION

When replacing safety signs, be sure to install them in the locations shown. Detailed description of the safety signs are given as follows:

1. Read Operator’s Manual (shown on display only) Use Operator’s Manual to make yourself thoroughly familiar with machine’s controls and its maintenance (This symbol will also be displayed on the display).

RAIL14COM0180AA

2

RAIL14COM0170AA

3

RAIL14COM0181AA

4

2. Wear safety belt (shown on display only) Wear safety belt before driving (This symbol will also be displayed on the display).

3. Pinch points Maintain safety distance away from the Machine. Hazard of being crushed between front and rear frame of the machine.

Location: Near steering joint

2-14

2 - SAFETY INFORMATION

4. Danger zone Keep a safe distance.

Location: On the left and on the right on the front frame

RAIL14COM0182AA

5

RAIL14COM0188AA

6

RAIL14COM0168AA

7

5. Danger zone (Optional) Keep a safe distance from the edge cutter / beveler if in operation.

Location: On the yoke over the edge cutter

6. Entanglement hazard Keep safety distance away from rotating pulley and belt.

Location: Hydraulic tank

2-15

2 - SAFETY INFORMATION

7. Adjust when stationary Carry out adjustment or maintenance with engine stopped.

Location: Left door of the engine compartment

RAIL14COM0166AA

8

RAIL14COM0167AA

9

8. Risk of burn Do NOT touch Machine’s hot parts unless you made certain these are cooled down sufficiently.

Location: On the hydraulic tank and on the left side of the front frame over the exhaust

9. Cooling liquid Cooling liquid is harmful to health. Read the Operator’s Manual.

Location: On the right side of the front frame

RAIL14COM0164AA

2-16

10

2 - SAFETY INFORMATION

10. Explosion hazard Read Operation Manual before battery maintenance or when starting with jumper cables.

Location: On the left door of the engine compartment

RAIL14COM0189AA

11

RAIL14COM0169AA

12

RAIL14COM0186AC

13

11. Disconnect the wiring Before welding, disconnect the wiring, alternator, machine’s electronics and Engine Control Unit.

Location: On the left door of the engine compartment

12. Max machine height Pay attention when passing through places with height limitation.

Location: On the left on the rear frame

2-17

2 - SAFETY INFORMATION

13. Lifting the machine To lift the Machine use lifting device of adequate capacity.

Before lifting, secure the machine articulation.

Location: On the left on the rear frame

RAIL14COM0190AA

14

RAIL14COM0165AA

15

RAIL14COM0187AA

16

14. Lifting points Use only the points identified with this sign to lift the Machine.

Location On both sides of the frame

15. Hot coolant Danger of scalding. Do not open the expansion tank lid until the liquid cools down below 50 °C (122 °F).

Location: On the right side of the front frame

2-18

2 - SAFETY INFORMATION

16. Noise emitted External noise limit of the machine.

Location: On the left side of the rear frame

RAIL14COM0184AA

17

RAIL14COM0185AA

18

RAIL14COM0183AA

19

17. Jacking point Use only the points identified with this sign to jack the Machine.

Location: On both sides of the frames

18. Tie down points Use only the points identified with this sign to tie down the Machine.

Location: On both sides of the frames

2-19

2 - SAFETY INFORMATION

19. Run over hazard Keep clear of the machine Location: On the left side of the rear frame

RAIL14COM0796AA

2-20

20

3 - CONTROLS AND INSTRUMENTS

3 - CONTROLS AND INSTRUMENTS###_3_### Access to operator's platform

Cab access/exit WARNING Fall hazard!

When entering or exiting the cab, never use the control levers as handholds. Always mount and dismount the machine in a safe way. Maintain a three-point contact with steps, ladders, and/or handholds.

Failure to comply could result in death or serious injury.

W1340B

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

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

• 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 on or off the machine.

SS12C056

• 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.

3-1

1

3 - CONTROLS AND INSTRUMENTS

Operator's seat

Operator seat adjustments DANGER Loss of control hazard!

DO NOT make seat or steering adjustments while the machine is in motion. Ensure all adjustments are locked prior to use. Check the tightness of the securing screws and that the adjustment controls are working properly. Fitting and/or repairing the seat should only be performed by skilled personnel.

Failure to comply will result in death or serious injury.

D0008A

WARNING Avoid injury!

Before starting the engine, securely fasten the seat belt. The seat belt can help ensure your safety if it is properly used and maintained. Never wear a seat belt loosely or with slack in the belt system.

Never wear the belt if it is twisted or pinched between the seat structures.

Failure to comply could result in death or serious injury.

W0142A

1. Head rest position 2. Backrest position 3. Seat forward /backward position 4. Seat angle position 5. Seat springing stiffness according to weight indicator.

6. Seat cross motion

RAIL14COM0215AA

Seat belt WARNING Equipment failure could cause accident or injury!

Always fasten the seat belt securely before you operate the machine. Inspect seat belt parts for wear and damage. Replace any and all worn or damaged parts of the seat belt prior to operation.

Failure to comply could result in death or serious injury.

W0046C

To fasten the belt, pull the belt from the reel and push the tongue into the buckle end until a “click” indicates it is properly engaged.

To release, press the red release button on the buckle and remove the tongue from the buckle.

3-2

SS12C077

2

1

3 - CONTROLS AND INSTRUMENTS

Seat switch The machine is equipped with a seat switch (operator presence system). It is used to block the engine from starting or to stop the machine if no operator is in the seat.

If the operator stands up from the seat while driving and does not sit back down, the machine will come to a complete stop and the brake will automatically engage.

This will last 5 s and then one of the following will occur: • If the operator does not sit in the operator seat before the next 5 s elapse, the engine will shut down. For the subsequent engine start, the driver must sit down again, move the travel controller to the central (neutral) position, engage park brake switch, place the key in the “0” position, and then proceed with the standard starting procedure.

NOTICE: Always follow the stopping procedure described in this manual. Do not use the seat switch feature as a normal way to turn off the machine.

• If the operator sits in the operator seat before the next 5 s elapse, the engine will continue to run. However, the operator must move the travel controller into the central position (neutral) and then into the correct travel direction before continuing to drive at the selected speed.

3-3

3 - CONTROLS AND INSTRUMENTS

Forward controls

Steering column controls Use the lever (A) on the left-hand side of the column to control the steering column tilting forward or rearward.

Use the lever (B) on the right-hand side of the column to adjust the steering wheel up or down.

RAIL16COM0107AA

3-4

1

3 - CONTROLS AND INSTRUMENTS

Left-hand side controls

Left-hand armrest controls

RAIL16COM0007FA

1.

– Pumps sprinkling selector switch:

4.

• Select one of the two drum sprinkling pumps.

– Edge cutter selection switch: • It is used for turning on the edge cutter (final compactor).

• The pump operation is indicated on the display.

• This is a rotary style switch which has three positions: Left – Left edge cutter/final compactor down Center - Off, all edge cutter/final compactors up Right – Right edge cutter/final compactor down

• This is a rotary style switch which has three positions: Left – Front pump On Center – Off Right –Rear pump On 5.

– Sprinkling button:

2.

1

– Drum vibration selector switch: • This is a rotary style switch which has three positions: Left - Front drum vibrates Center - both drums vibrate Right - Rear drum vibrates

• This is a push style switch. Push the switch once to start the drum sprinkling function. Push the switch again to turn Off the sprinkling function.

• The function is displayed on the display.

6. Not used 3.

– Emulsion sprinkling button (Only wheel version): • Not used

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3 - CONTROLS AND INSTRUMENTS

Right-hand side controls

Right-hand armrest controls

RAIL16COM0007FA

1.

2.

– Travel controller (shown as sitting in the seat facing forward):

– CRAB mode switches: • To set the drums in the CRAB mode, use these push switches on the travel control: 2A Crab mode Right - Press and hold until full crab steer right is reached, then release.

2B Crab mode Left - Press and hold until full crab steer left is reached, then release.

• The travel controller is used for braking the machine and setting the direction and speed of travel.

• Travel controller has five positions: P - Parking brake - machine parking brake activated N - Neutral - the machine is not braked, idle engine speed set up F - Forward travel R - Reverse travel • The machine braking is indicated by lighting up the brake indicator lamp on the display.

1

• The function is displayed on the display.

• Press and hold both switches (2A) and (2B) until straight forward (no crab steer) is reached, then release.

3.

• The travel speed corresponds to the displacement of the travel controller from the center position.

– Edge cutter up: • Use this push switch to move the edge cutter to the transport position. Press and hold until fully raised, then release.

4.

– Vibration switch: • Use this push switch to turn on or off the vibration function.

• The vibration function is displayed on the display

3-6

3 - CONTROLS AND INSTRUMENTS

5.

• This switch is used for turning on/off the hazard lights - the function is indicated by flashing the indicator lamp in the warning light switch.

• Use this push switch to move the edge cutter to the working position. Press and hold until fully lowered, then release.

• This is a rotary switch which has two positions: Left - Hazard warning lights On. Right - Hazard warning lights Off.

– Vibration amplitude switch

6.

– Hazard light switch

11.

– Edge cutter down:

• This is a rotary switch which has two positions: Left - Amplitude II switched On Right - Amplitude I switched On

– Headlight switch

12.

• This switch is used for turning On/Off the parking and low beam lights.

7.

– Vibration mode selector switch

• This rotary switch has three positions: Left - Off Center - Parking lights Right - Low beam lights

• This switch is used to switch On vibrations in manual or automatic mode.

• This is a rotary switch which has two positions: Left MAN - Manual mode, vibrations can be switched On even with stationary Machine Right AUT - Automatic mode to switch Off/On vibrations automatically

8.

13.

• This switch is used for turning On/Off the rear lights.

• This rotary switch has two positions: Left - Off Right - On

– Turn indicators switch • This switch is used to switch On or Off the turn signal indicators.

• This is a rotary switch which has three positions: Left - Left turn signal indicator On. Center - All turn signal indicators Off. Right - Right turn signal indicator On.

9.

14.

– Additional lights switch • This switch is used for turning On/Off the additional lights.

• This rotary switch has three positions: Left - Additional lights Off Center - Drum additional lights On Right - Cab additional lights On

– Emergency brake pushbutton • Push the switch down to engage the machine emergency brake.

Pull the switch up to release the machine emergency brake.

15. Ignition switch

• When the switch is pressed down, the brake indicator and charging indicator lamps on the display turns on.

10.

– Rear lights switch

– Warning horn button — Push to sound horn.

3-7

• The ignition switch has three positions Counterclockwise - Ignition Off - the key can be inserted and removed in this position.

First position clockwise - Ignition On - this is the normal position while the engine is running.

Second position clockwise - Crank Engine - this position is used to start the engine.

3 - CONTROLS AND INSTRUMENTS

Rearward controls

Rear panel 1.

– Controller Area Network (CAN) 2 connector • Connector for the machine control unit CANBUS connection.

• Serves for connecting a laptop to assure proper communication between control units.

2.

– Controller Area Network (CAN) 1 connector • Connector for the machine control unit CANBUS connection.

• Serves for connecting a laptop to assure proper communication between control units.

3.

– ACE Computer Unit (ACU) connector • Serves for connecting a laptop to assure proper communication between control units. Using the program ACE Parameter Manager, you can change parameters in ACU or download them to a computer.

4.

– ACE Force Intelligent Compaction connector • It is used for connecting a laptop to assure proper communication between the ACU, ACE display and RC computer.

5.

6.

– Engine diagnostics connector

– Service switch • It is used for disabling the seat sensor function. The engine will keep running, when the operator leaves the seat.

To disable the seat sensor, push down on the top lever and push the bottom of the switch. To enable the seat sensor, push the top of the switch.

NOTICE: Use the switch only for maintenance and service operations.

3-8

RAIL16COM0009AA

1

3 - CONTROLS AND INSTRUMENTS

7. 12 V Power socket (if equipped) • It is used for connecting a lamp or other equipment.

3-9

RAIL14COM0205AA

2

RAIL16COM0030AA

3

3 - CONTROLS AND INSTRUMENTS

Overhead controls

Overhead panel Cab units

RAIL16COM0019FA

1.

– Rear window heating switch • This rotary switch has two positions: Up– Rear window heating On Bottom – Rear window heating Off

2.

1

3.

• This rotary switch has three positions: Top – Turned Off Center – Low speed On Bottom – High speed On

– Window washer switch • This rotary switch has three positions: Top – Front window washing On Center – Off Bottom – Rear window washing On

– Front wiper selector switch

4.

– Rear wiper selector switch • This rotary switch has three positions: Top — Turned Off Center – Low speed On Bottom – High speed On

3-10

3 - CONTROLS AND INSTRUMENTS

5.

6.

– Rotating beacon switch (Optional) • This rotary switch has two positions: Top — Turn on the beacon light Bottom – Turn off the beacon light

– Cab additional lights switch • This rotary switch has two positions: Top — Turn on the additional cab lights Bottom – Turn off the additional cab lights NOTE: Indicator lamp inside switch lights when lights are on.

NOTE: Indicator lamp inside switch lights when rotating beacon is on.

7.

– Cabin lighting

8.

Radio (Optional equipment)

9.

Rear mirror NOTICE: Maintain the mirrors clean and properly adjusted!

NOTE: All controls not identified on the overhead panel are heating and air conditioning controls. Refer to 3-29 for identification and operation of these controls.

Non cab units

1.

– Rotating beacon switch (Optional) This rotary switch has two positions: Top — Turn on the beacon light Bottom – Turn off the beacon light

NOTE: Indicator lamp inside switch lights when rotating beacon is on.

2.

– Cab additional lights switch This rotary switch has two positions: Top — Turn on the additional cab lights Bottom – Turn off the additional cab lights

RAIL16COM0112AA

NOTE: Indicator lamp inside switch lights when lights are on.

3-11

2

3 - CONTROLS AND INSTRUMENTS

Display

Display unit Your machine is equipped with a multifunctional instrument to display the parameters of the engine and machine functions.

With the display you can also control the machine functions such as: • Maximum engine speed • Intensity of drum sprinkling • Vibration frequency • Travel speed • Differential lock • Ignition lock • Transport mode • Brake test The display also displays the error messages and system informations.

Screen buttons The display has the following buttons: 1. Function select buttons 2. Horizontal navigation buttons 3. Vertical navigation buttons 4. “OK” button

RAIL14COM0299AA

1

RAIL14COM0378AA

2

PIN locking Your machine is supplied with two PIN cards, which provides the PIN code corresponding to your machine.

Use this pin code to activate or deactivate the ignition lock and the transportation mode functions.

For activation and deactivation of the ignition lock function or transportation mode function, use the same PIN code.

See the PIN code on the PIN card in the documentation set.

In the event of the PIN card loss, contact your dealer.

3-12

3 - CONTROLS AND INSTRUMENTS

Enter the PIN code when prompted.

To enter the PIN code number, use the display buttons.

Each button corresponds to a number. Refer to the image for reference.

NOTE: Refer to 3-27 for complete procedure for ignition lock or transport mode activation and deactivation.

RAIL14COM0299AA

Display screens The information is displayed in three different screens as follows: • Operations screen • Information screen • Service screen Detailed informations on each screen can be found in the following section.

Vertical navigation buttons ( between the screens.

) are used to navigate

Press the button once to view the corresponding screen.

To set the following screen as the home screen, hold the button for 5 seconds.

3-13

3

3 - CONTROLS AND INSTRUMENTS

Display screens Operations screen – Controls

RAIL14COM0304FA

1

Use buttons corresponding to the symbols to control the function

1.

3.

– Maximum engine speed • This feature is selected by pressing the left upper button.

• Use this feature to set the unit to the maximum engine speed in rpm (nominal engine speed should be 2200 RPM). When activated, the icon will be illuminated.

Press the left upper button a second time to return to idle.

2.

– Drum sprinkling • Use this feature to set the drum sprinkling intensity • The selected sprinkling intensity is displayed on the screen. The sprinkling intensity can vary from 0% (Drum sprinkling Off) to 100% (Continuous drum sprinkling) • Use the left-middle selection button (+) to increase and left-lower selection button (-) to decrease the sprinkling intensity.

3-14

—

– Vibration frequency

• Use this feature to set the drum vibration frequency.

• Use the lower-left selection button (-) to reduce and lower-right selection button (+) to increase the vibration frequency • Selected frequency will be displayed in the screen.

• Refer to the general specifications section for the operating frequencies for your model.

3 - CONTROLS AND INSTRUMENTS

5.

4.

• Use this feature to turn on and turn off the differential lock.

– Travel speed • Use this feature to select the speed gear. The speed and engine speed for the selected gear is as follows: Speed gear 0 1 2 3 4 5

Forward speed 3 km/h (1.9 mph) 2 km/h (1.2 mph) 3 km/h (1.9 mph) 4.5 km/h (2.8 mph) 6 km/h (3.7 mph) 10.5 km/h (6.5 mph)

– Differential lock

Rearward speed 3 km/h (1.9 mph) 2 km/h (1.2 mph) 3 km/h (1.9 mph) 4.5 km/h (2.8 mph) 6 km/h (3.7 mph) 10.5 km/h (6.5 mph)

• This feature can be selected by pressing the rightupper selection button.

NOTICE: The differential lock is used to prevent the drum from slipping when crossing difficult terrain or loading onto a trailer.

Engine speed 1600 RPM 1300 RPM 1600 RPM 1600 RPM 1600 RPM 1600 2200 RPM

• Use the right-lower selection button (-) to reduce the speed gear and right-middle selection button (+) to increase the speed gear.

• Selected gear and machine speed will be displayed on the screen.

NOTE: The speed gear 0 is set as the starting gear 15 minutes after the switch box is turned off.

NOTE: Working functions (vibration, sprinkling, crab, etc...) of the machine are locked and disabled in the speed gear 0.

3-15

3 - CONTROLS AND INSTRUMENTS

Operations screen – Notifications

RAIL14COM0314AA

1.

4.

– Water level indicator • The scale below this indicator shows the water level in the tank.

2.

– Indicator lamps of turn indicators

– Fuel gauge • The scale below this indicator shows the fuel level in the tank.

5.

• These indicators show that the turn indicators are On.

3.

2

– Infra thermometer indicator (optional) • This indicator shows the compacted surface temperature in the range of 0 - 200 °C (32 - 392 °F).

3-16

– Right edge cutter / beveler indicator • This indicates that the edge cutter / beveler on the right side of the machine is enabled.

3 - CONTROLS AND INSTRUMENTS

6.

8.

– Drum vibration indicator • This indicator shows the drum vibrations are On (shows if the only the front, only the rear, or both the drums are vibrating).

• This indicator shows the amplitude and frequency of vibrations selected using the vibration frequency selection switches.

9.

7.

– Vibration gauge

– Machine extended track indicator

– Left edge cutter / beveler indicator • This indicates that the edge cutter / beveler on the left side of the machine is enabled.

(crab) • This indicator shows the drum settings.

• Range: 0 - 170 mm (0 - 6.7 in)

3-17

3 - CONTROLS AND INSTRUMENTS

RAIL16COM0022FA

1.

– Engine failure indicator

3.

• This indicator indicates an engine failure.

– Engine lubrication indicator • This indicator indicates an engine lubrication failure.

• If this indicator appears, the engine will shutdown - the machine will stop and the parking brake will be enabled.

• If this indicator appears, the engine will shutdown - the machine will stop and the parking brake will be enabled.

NOTICE: If this indication appears, the engine can be started only after the defect is repaired.

2.

3

NOTICE: If this indication appears, the engine can be started only after the defect is repaired.

– Engine coolant level indicator 4.

• This indicator indicates low engine coolant level.

• If this indicator appears, the engine will shutdown - the machine will stop and the parking brake will be enabled.

NOTICE: If this indication appears, the engine can be started only after the coolant is refilled to the correct level.

3-18

– Engine overheating indicator • This indicator indicates a high temperature of the engine.

• If this indicator appears, the engine will shutdown - the machine will stop and the parking brake will be enabled.

NOTICE: If this indication appears, the engine can be started only after the defect is repaired.

3 - CONTROLS AND INSTRUMENTS

5.

11.

– Battery charging indicator

• This indicates that the fuel filter cartridge(s) are clogged.

• It indicates that the battery charging function is correct. After the key on the ignition switch is turned to position I, this indicator lamp must light up and go out after the engine startup.

NOTICE: If this indication does not goes off after engine startup, stop the engine immediately and rectify the defect.

6.

– Fuel filter indicator

NOTICE: If this indicator appears, immediately replace the engine filter and pre-filter cartridges!

12.

– Engine pre-heating indicator • This indicator indicates that the engine is warming up before the cold start.

– Air filter clogging indicator

NOTICE: Start the engine only when this indicator goes off.

• This indicator indicates that the filter(s) cartridge is clogged above the allowed limit.

NOTICE: If this indication appears on the screen, stop the machine and clean or replace the filter cartridge(s) immediately.

13.

– Sprinkling pump indicator • This indicator indicates that the sprinkling pump is on.

7.

– Hydraulic oil filter clogging indicator • This indicator indicates that the filter cartridge is clogged.

14.

• This indicator and an audible signal indicate a error on the control unit.

• When “1” appears on this indicator, it indicates that the main hydraulic filter is clogged. When “2” appears on this indicator, it indicates that the optional hydraulic oil filer is clogged (if equipped). “3” is not used on this unit.

8.

• In case of a serious failure, the machine changes to the emergency mode (travel gear 0, working functions disabled).

• An error message will be displayed. After the machine is turned off using the key, the error will be reset. After the next start-up, the machine can be operated in a usual way.

– Hydraulic oil level indicator • This indicator indicates low hydraulic oil level.

• If the error occurs repeatedly, shut down the machine and call your dealer for service. For easier communication with your dealer, check error messages on the service screen (3rd screen) and copy down codes of all diagnosed errors of the engine control unit and machine control unit.

• If this indicator appears, the machine will stop and the parking brake will be enabled.

9.

– Master caution indicator

– Parking brake indicator • This indicator indicates that the parking brake is enabled.

15.

10.

– Diesel Exhaust Fluid (DEF) level • not used on this model

– Water in fuel filter indicator • This indicates water in the fuel filter.

NOTICE: If this indicator appears, drain the water from the fuel pre-filter.

3-19

3 - CONTROLS AND INSTRUMENTS

• not used on this model 16.

– High temperature of exhaust gasses • not used on this model

18.

– Selective Catalytic Reduction (SCR) catalyst crystallization • not used on this model

17.

– Diesel Exhaust Fluid (DEF) quality

3-20

3 - CONTROLS AND INSTRUMENTS

Information screen

RAIL14COM0306FA

4

ter the start-up, the operator is prompted to check the brakes every 24 hours).

1.

– Ignition lock control • This feature is used for turning on/off the ignition lock.

4.

– Worked hours indicator amplitude II

2.

• This indicator indicates the total time the vibrations were On in Amplitude II

– Vibration frequency indicator • This field indicates the vibration frequencies of the front and rear drum. 0 Hz indicates that the vibrations are turned Off.

– Worked hours indicator -

5. amplitude I

3.

• This indicator indicates the total time the vibrations were On in Amplitude I

– Brake test control • This indicator will light up to remind the operator to check the machine brakes for correct operation (af-

3-21

3 - CONTROLS AND INSTRUMENTS

6.

– Tachometer

8.

• This indicator shows the engine speed in rpm.

7.

– Hourmeter • This indicator shows the actual number of hours the engine is On. Periodic maintenance should be carried out as per the engine hours.

– Engine load indicator • This indicator shows the load on the engine in percentage.

3-22

3 - CONTROLS AND INSTRUMENTS

9.

14.

– Battery voltage indicator

• This indicator shows the engine coolant temperature.

• This indicator shows the battery voltage.

10.

– Fuel consumption indicator • This indicator shows the current fuel consumption.

11.

15.

– Engine lubrication pressure • This indicator shows the engine oil pressure.

12.

– Transport mode control • This indicator is used for setting the machine to the transport mode. Activation and deactivation is done by entering PIN.

13.

– Coolant temperature indicator

– Hydraulic oil temperature indicator • This indicator shows the hydraulic oil temperature.

3-23

– Date and time indicator • This indicator shows the current date and time. To set the date and time, press and hold the OK button for 5 seconds. Use vertical and horizontal navigation buttons to set the date and time.

3 - CONTROLS AND INSTRUMENTS

Service screen

RAIL16COM0024FA

The screen is used for basic diagnostics of inputs into the machine control unit and for displaying error messages.

1.

– Extended track button (CRAB) - right

2.

– Edge cutter button - down

5

9.

– Manual water sprinkling button

10.

– Not used

11.

– Indication switch of hydraulic oil filter clogging

3.

4.

5.

6.

– Vibration button 12.

– Hydraulic oil level switch

13.

– Thermostat sensor

14.

– Amplitude I and II sensor

15.

– Automatic and manual vibration sensor

– Edge cutter button - up

– Neutral sensor

– Brake sensor

7.

– Sprinkling pump switch 1

8.

– Sprinkling pump switch 2

3-24

3 - CONTROLS AND INSTRUMENTS

16.

– Drum vibration sensor

22.

– Seat switch

17.

– Not used

23.

– Not assigned

18.

– Emergency brake switch

24.

– Extended track button (CRAB) - left

19.

– Not assigned

25.

– Edge cutter switch - right

20.

– Not assigned

26.

– Edge cutter switch - left

21.

– Service switch

27.

– Start-up conditions met

3-25

3 - CONTROLS AND INSTRUMENTS

RAIL16COM0025FA

1.

— rearward

– Travel lever sensor - forward,

2.

– Crab sensor

3.

– Infra-thermometer switch (Optional)

4.

– Fan speed

5.

– Water level sensor

6.

– Fuel level sensor

7.

– Display error messages The OK button is used for switching over between error lists of the engine and machine control unit. The arrows are used for moving in the error list.

6

8.

– Occurrence counter (OC) (failure source information)

9.

– Failure Mode Identifier (FMI) (failure source information)

10.

– Suspect Parameter Number (SPN) (failure source information)

11.

– Engine error message

12.

– Occurrence counter

13.

—

– Not used

14.

—

– Not used

NOTE: If faults keep reoccurring, record the FMI (reference 9) or SPN (reference 10) numbers and contact your dealer.

3-26

3 - CONTROLS AND INSTRUMENTS

Ignition lock Ignition lock option in the information screen is used for turning on/off the ignition lock.

To lock or unlock the machine, proceed as follows:

1.

Press the ignition lock button

2. The screen will prompt to enter PIN 3. Enter the PIN as explained in Page 3-12 4. Confirm by pressing the OK button for 4 seconds (When the PIN is accepted, an audible alarm sounds).

Ignition lock is automatically enabled 15 minutes after the ignition is switched Off.

3-27

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3 - CONTROLS AND INSTRUMENTS

Transport mode Transport mode is used for setting the machine to the transport mode. Activation and deactivation is done by entering PIN. Transportation mode on the machine is set by the manufacturer and serves for shipment and transportation of the machine to a customer.

Once these function is enabled: • Differential lock is set to On (Enabled) • Speed gear set to 0 - (Machine speed: 0 - 2 km/h (0 1.2 mph)).

• Working functions (vibration, sprinkling, crab, etc...) are disabled.

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• Speed gear changing is disabled.

To set the machine in transport mode, proceed as follows:

1.

Press the transport mode button

2. The screen will prompt to enter PIN 3. Enter the PIN as explained in Page 3-12 4. Confirm by pressing the OK button for 4 seconds (When the PIN is accepted, an audible alarm sounds).

NOTE: To disable the transport mode use the PIN and above procedure.

3-28

3 - CONTROLS AND INSTRUMENTS

Climate controls

Heating and air conditioning controls

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1.

– Rear window heating switch

3.

• This control is used for turning on the rear window heating.

– Heater fan switch

– Fan speed switch • This control is used to for controlling the air flow • This switch has four positions: Position 0 – Off Position 1 – Minimum Position 2 – Medium Position 3 – Maximum

• This switch has two positions, the function is indicated by the indicator lamp in the switch: – Off – On

2.

1

4.

– Thermostat

• This control is used for turning on the cab heater fan.

• This switch is used to control the outlet air temperature.

• This switch has three positions, the function is indicated by the indicator lamp in the switch: Position 1 – Off Position 2 – Low Position 3 – High

• The positions marked in the switch are as follows: Off MIN MAX

3-29

3 - CONTROLS AND INSTRUMENTS

Heating control Heating control knob (1) is used to switch On the cabin heating.

Make continuous control from MIN position (valve closed) to MAX position (valve fully open) for the amount of liquid flowing to the heating body.

NOTICE: Adjust the heating valve before driving. Do not adjust during driving.

Cabin ventilation air filter The filter (2) contains replaceable cartridges, which filters the impurities from the air.

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Cab features

Interior component locations Draw bar for window unlocking Use the draw bar to keep the window in locked position.

Storage Storage compartments are located behind the operator’s seat.

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4 - OPERATING INSTRUCTIONS

4 - OPERATING INSTRUCTIONS###_4_### Commissioning the unit

Before starting the engine WARNING Unexpected machine movement!

Before starting the engine, move all operating controls to neutral or park lock position. This prevents accidental movement of the machine or start up of power-driven equipment.

Failure to comply could result in death or serious injury.

W0302A

First use Before starting your unit for the first time, make the following checks: • Make sure the engine is properly lubricated and greased as described in the Maintenance section of this manual.

• Check the oil level in the engine crankcase. See the maintenance section of this manual.

• Check that the fuel tank is filled with clean fuel that meets the specifications given in this manual.

• Check the engine, hydraulic system, fuel and cooling system for air or oil leaks.

• Check that the alternator and compressor belts are adjusted correctly.

• Remove any water or sediment from the water separator of the fuel tank and primary fuel filter.

• Check the coolant level in the coolant recovery bottle. Add 50 % water and 50 % CNH XHD HEAVY DUTY COOLANT / ANTI-FREEZE as needed.

Daily inspection Check the following daily before starting the engine: • Engine oil level • Hydraulic oil level • Coolant level • Fuel tank level • Water level • No loosened, worn or missing parts NOTICE: Refer to “Maintenance” chapter for more details.

NOTICE: Do NOT load the Machine at its full capacity when putting the new Machine into operation or following its major overhaul during the first 30 hours!

4-1

4 - OPERATING INSTRUCTIONS

Seat belts WARNING Avoid injury!

Before starting the engine, securely fasten the seat belt. The seat belt can help ensure your safety if it is properly used and maintained. Never wear a seat belt loosely or with slack in the belt system.

Never wear the belt if it is twisted or pinched between the seat structures.

Failure to comply could result in death or serious injury.

W0142A

WARNING Fall hazard!

The instructional seat shall only be used when training a new operator or when a service technician is diagnosing a problem. Do not permit others, especially children, to ride in the seat. Keep the cab door(s) closed. Wear a seat belt at all times.

Failure to comply could result in death or serious injury.

W0301A

Always securely fasten your seat belt before operating the unit. From time to time, carefully inspect the seat belts for worn areas and replace belts when needed. Adjust the position of the operator’s seat. Pull the seat belt completely across your body. Push the metal eye into the buckle until it locks.

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Adjust the position of the seat belt as low across your body as possible.

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4 - OPERATING INSTRUCTIONS

To release the seat belt, push the button in the center of the buckle and separate the buckle and metal eye.

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Steering column adjustment DANGER Loss of control hazard!

DO NOT make seat or steering adjustments while the machine is in motion. Ensure all adjustments are locked prior to use. Check the tightness of the securing screws and that the adjustment controls are working properly. Fitting and/or repairing the seat should only be performed by skilled personnel.

Failure to comply will result in death or serious injury.

D0008A

The steering column and steering wheel can be adjusted to suit the operator. To move the steering column forward or rearward, pull lever (A) on the left-hand side of the column. To adjust the steering wheel up or down, pull lever (B) on the right-hand side of the column.

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4

4 - OPERATING INSTRUCTIONS

Starting the unit

Starting the engine DANGER Run-over hazard!

Start engine only from operator’s seat. If you bypass the safety start switch, the engine can start with the transmission in gear and the machine will move. DO NOT short or connect across terminals of the starter solenoid.

Failure to comply will result in death or serious injury.

D0102A

WARNING Hazard to bystanders!

Always sound the horn before starting the machine. Make sure the work area is clear of other persons, domestic animals, tools, etc. before you operate the machine. Never allow anyone in the work area during machine operation.

Failure to comply could result in death or serious injury.

W0304A

WARNING Inhalation/asphyxiation hazard!

Make sure there is proper ventilation before starting the engine.

Failure to comply could result in death or serious injury.

W0091A

WARNING Hazard to bystanders!

ALWAYS make sure the work area is clear of bystanders and domestic animals before starting this procedure. Know the full area of movement of the machine. Do not permit anyone to enter the area of movement during this procedure.

Failure to comply could result in death or serious injury.

W0245A

NOTICE: Do NOT load the Machine at its full capacity when putting the new Machine into operation or following its major overhaul during the first 30 hours!

4-4

4 - OPERATING INSTRUCTIONS

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4-5

4 - OPERATING INSTRUCTIONS

Start the engine as follows: 1.

Switch ON the power cut-off switch.

2.

Set the travel control lever (1) to the parking brake position (P) –

3.

Sit down on the seat.

4.

Check that the emergency brake switch (2) is not enabled.

5.

Insert key in the ignition switch (3) in position 0 and switch over to position I.

6.

If the ignition lock function was enabled, refer to 3-27 and turn off the ignition lock.

7.

The brake (5), charging (6) and preheating (7) indicators will light up on the display as shown in image 2.

8.

Wait until the preheating indicator lamp goes out.

9.

Use the horn switch (4) to sound the horn to warn any bystanders

.

10. Turn the ignition key (3) to position II to start the engine.

11. The charging indicator (6) must go out after the starting is completed.

NOTE: If the charging indicator (6) does not goes Off, turn Off the engine and rectify the defect.

12. After the machine started moving, the brake indicator (5) goes out.

NOTICE: If starting is unsuccessful, turn the ignition key back to position 0 and repeat steps 5 through 10. If the engine does not start even after 3 attempts, check for cause.

NOTICE: Never engage the starter motor for more than 30 seconds. If the starting is unsuccessful, wait for 2 minutes before starting the engine again.

NOTICE: Following the engine start, run the engine idle at increased rpm for 3 to 5 minutes. Do not let the engine idle for over 10 minutes. Idling longer than 10 minutes could cause fouling of injectors or piston or valves may get seized.

NOTICE: Do not load the engine at full power if the coolant temperature is less than 40 °C (104 °F).

Brake test It is recommended to carry out the brake test daily after the first engine start-up.

The machine can continue operations even if the brake test is not performed (the brake test record is saved in the machine control unit) and the brake test can be carried out later.

Follow the procedure below to carry out the brake test

1. Set the travel control lever (1) to the parking brake position (P) –

.

2. On the display, navigate to the “Information screen” using the horizontal navigation buttons.

3. Press the right-upper selection button which corresponds to the “Brake test” option on the screen.

4. Change the travel control lever to the neutral position (N) and then to forward (F).

5. When the test is successful, “TEST OK” appears on the screen.

6. If the test is not successful and “TEST NOT OK” appears on the screen, repeat the test. If the test is still not successful, contact your dealer immediately.

4-6

4 - OPERATING INSTRUCTIONS

Stopping the unit

Stopping the machine

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To stop the machine and its engine, do as follows: 1. Press the button (2) on the travel control (1) to switch off the vibration.

2. Stop the machine by changing the travel control (1) to the neutral position (N).

3. Brake the machine by changing the travel control (1) to the parking brake position (P).

NOTICE: When the engine is not running, the travel control lever (1) should always be in parking brake position.

4. Leave the machine idle for 3 minutes and then turn the key in the ignition switch (3) to position 0 Off. Remove the key from the ignition and tilt back the ignition switch lid to close it.

NOTICE: Run the engine in idle for 3 minutes before turning Off. This will help the engine and turbo charger cool slowly and evenly.

5. Switch the power cut-off switch to the Off position.

NOTICE: Wait 60 seconds after shutting off the ignition key before shutting off the power cut-off switch. This time is required for the Engine Control Module (ECM) to save the data.

4-7

4 - OPERATING INSTRUCTIONS

Emergency stop Use this option only when it is not possible to stop the engine using the ignition key or by moving the travel control lever to parking brake position.

NOTICE: Do not use the emergency brake for turning off the engine in normal operation.

Switching emergency brake On 1. After pressing the emergency brake button (4), the machine is braked and the engine stops.

2. The parking brake indicator lamp (5) lights up on the display.

Switching emergency brake Off 1. Turn the emergency brake button (4) in the direction of arrows.

2. The parking brake indicator lamp keeps lighting on the display.

3. Move the travel control (1) to the position (P). You can restart the engine in this position.

4-8

4 - OPERATING INSTRUCTIONS

Moving the unit

Machine travel and reversing WARNING Run-over hazard!

Only operate the machine when sitting in the operator’s seat. Do not try to bypass the operator presence safety system by placing heavy objects on the seat.

Failure to comply could result in death or serious injury.

W0318A

WARNING Hazard to bystanders!

Always sound the horn before starting the machine. Make sure the work area is clear of other persons, domestic animals, tools, etc. before you operate the machine. Never allow anyone in the work area during machine operation.

Failure to comply could result in death or serious injury.

W0304A

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4-9

1

4 - OPERATING INSTRUCTIONS

Selecting travel direction Start the engine.

Move the travel control lever (1) from the parking brake (P) to the neutral position (N) – brakes and the parking brake indicator goes out. The engine idle speed is set up.

. This will release the

Move the travel control lever (1) to the position 0 and select the travel direction ( F/R ).

The engine rpm will be set according the to the preset gear.

Selecting travel speed The travel speed corresponds to the movement of the travel control lever (1) from the position zero (0).

The travel speed can be changed using the speed buttons MIN (turtle) (2) and MAX (rabbit) (3) on the operations screen of the display (4).

Speed gear 0 1 2 3 4 5

Forward speed 2 km/h (1.2 mph) 2 km/h (1.2 mph) 3 km/h (1.9 mph) 4.5 km/h (2.8 mph) 6 km/h (3.7 mph) 11 km/h (6.8 mph)

Rearward speed 2 km/h (1.2 mph) 2 km/h (1.2 mph) 3 km/h (1.9 mph) 4.5 km/h (2.8 mph) 6 km/h (3.7 mph) 11 km/h (6.8 mph)

Engine speed 1600 RPM 1300 RPM 1600 RPM 1600 RPM 1600 RPM 1600 - 2200 RPM

NOTICE: The speed gear 0 is set as the starting gear after 15 minutes after the ignition switch is turned to Off. NOTE: Working functions (vibration, sprinkling, crab) of the machine are locked in the speed gear 0.

When the travel control is changed to the opposite position, within 1 second the machine will stop - the parking brake will be enabled, the engine will keep running. The machine can start moving after the travel control is changed to the neutral position (N) and the travel direction (F/R) is selected.

The machine can be stopped immediately by changing the direction of travel through position zero 0.

To move the machine, travel control should be moved to neutral position and then the travel direction is selected

Crab function

The function is used for offsetting one of the drums when working at the curbings.

1. Press the button (5) to offset the front drum right.

2. Press the button (6) to offset the front drum right.

3. The drum setting is displayed on the display (4).

4. The maximum mutual drum offset to both sides is 17 cm (6.7 in).

To reset the drum offset, press and hold both the buttons (5) and (6).

4-10

4 - OPERATING INSTRUCTIONS

Parking the unit

Parking the machine and stopping the engine 1. Shut down the machine on flat and solid surface at a point with no potential of natural hazard (landslides, possible flooding, etc...).

NOTICE: Run the engine in idle for 3 min before turning Off. This will help the engine and turbo charger cool slowly and evenly.

NOTICE: Wait 60 seconds after shutting off the ignition key before shutting off the power cut-off switch. This time is required for the Engine Control Module (ECM) to save the data.

2. Set the travel control to the brake position (P).

3. Switch off the power cut-off switch.

4. Clean the machine to remove dirt (scrapers and drums).

5. Make overall inspection of the machine and repair any defects that have occurred during operation.

6. Lock the machine covers and its cabin.

4-11

4 - OPERATING INSTRUCTIONS

4-12

5 - TRANSPORT OPERATIONS

5 - TRANSPORT OPERATIONS###_5_### Road transport

Traveling on public roads This type of machine is not intended for driving on public road. When necessary to move the roller to a different location, the machine should be transported on a trailer.

Shipping transport

Machine transport (on a trailer) When on the road, the vibratory roller should be transported on a transport vehicle. The transport vehicle should be capable of hauling the weight of the vibratory roller.

When loading and unloading the vibratory roller, the vehicle transporting the unit must have its brakes applied and be mechanically protected against accidental movement using wheel chocks (3).

The vibratory roller on the transport vehicle must be properly tied (1) and mechanically secured against all movement as well as against tipping. The drums must be secured using wheel chocks (2).

NOTE: Check your local laws and regulations for road transport.

5-1

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5 - TRANSPORT OPERATIONS

Loading the machine with a ramp When loading the machine using a ramp, the ramp must have appropriate loading capacity, antislip surface, and have a flat surface. The maximum permissible incline of the ramp must not be more than 30 °.

1. Set the scrapers in the working position.

2. Use speed gear 0.

3. The differential lock is ON. 4. Working functions of the machine (sprinkling, vibration, crab) are all turned Off.

5-2

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5 - TRANSPORT OPERATIONS

Loading the machine with a crane The machine may also be lifted for loading into the vehicle.

Before lifting the machine, use pin (1) and safety pin (lock) (2) to secure the joint before loading.

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5

1. Observe safety regulations when loading and unloading. Use lifting device of adequate loading capacity.

2. Lift the machine only using the lifting lugs.

3. Only a trained operator can lift the machine.

4. Keep the personnel and bystanders off/beneath the hanging area.

5-3

5 - TRANSPORT OPERATIONS

Recovery transport

Towing the machine Follow the safety precautions below for safely towing the machine: • Use only intact tow ropes or towing bars with a sufficient capacity (1.5 times higher than the weight of the towed machine). Never use chains for towing the machine.

• It is necessary to keep the minimum departure from the direct towing angle. The maximum departure is possible at an angle of 30°.

• When towing, it is necessary to ensure the continuous movement. Do not exceed a towing speed of more than 2 km/h (1.2 mph). Do not tow the machine for a longer distance than 0.3 km (0.19 miles).

• The size of the tow vehicle must match or exceed the size of the vehicle being towed. It must have sufficient traction force (power), weight and brake effect.

• Do not start the engine when towing.

• When towing a disabled machine downhill, use a rope or tow bar and another tow vehicle connected to the rear of the disabled machine. This will prevent an uncontrolled downhill movement of the disabled unit.

Machine may be towed for two reasons: 1. Machine is stuck in soft and muddy ground A. If the engine is running and travel drive and steering system works, tow the machine for a short distance until unit is on firm ground.

NOTE: During this procedure, an operator may stay on the machine to steer the machine.

B. If the engine is not running or travel drive and/or steering system does not work, follow the same steps as a broken down machine.

2. Machine failed (broken down) RAIL16COM0132AA

A. Chock the drums to prevent the machine movement.

B. Brake-off and short circuit the hydraulic system as explained below to disable all the brakes.

1

NOTE: A decal which shows the tow valve procedure is placed in the machine. Follow the instructions in the following tow procedure for proper operation of the tow valve when towing the machine.

C. Make sure that there are no persons in the machine being towed.

5-4

5 - TRANSPORT OPERATIONS

Towing procedure The machine is equipped with two lugs on front frame and with two lugs on rear frame.

Use only the towing lugs for towing.

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1. Switch Off the battery master switch (1).

Short circuit the travel pumps 2. Remove the lever (1).

5-5

5 - TRANSPORT OPERATIONS

3. Adjust washer from position A to position B.

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4. Reinstall the lever (1) in original position and move the lever to position C.

Machine brake off 5. Remove the lever (2).

6. Adjust washer from position A to position B.

5-6

5 - TRANSPORT OPERATIONS

7. Reinstall the lever (2) in original position and move the lever to position (D) .

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8. Switch On the battery master switch (1).

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9. Turn the ignition key switch to Position I. NOTE: If the key remains in position I for more than 15 seconds, an audible alarm will sound indicating that the battery is discharging.

10. Remove the hand pump control lever from the storage position in the left-hand service door.

5-7

5 - TRANSPORT OPERATIONS

11. Place the control lever into the hand pump (5) and pump the brake circuit until the brake indicator (4) goes out on the display.

NOTE: Brake indicator going off in the display indicates that all the brakes are disabled (machine brakeoff).

NOTICE: During towing, there might be loss in the pressure in the brakes due to leakage. This will lead to brakes being applied and the brakes becoming hot. The parking brake warning light in the display may come on if the pressure is lost. Regularly check the brake temperature and indicator in the display. Stop towing and apply pressure in case of a pressure loss.

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NOTICE: When towing is complete, secure the machine with chocks and apply the brakes. Refer to the following procedure to restore the machine to its normal function after towing is complete.

Restoring machine after towing After the towing is complete, restore the machine to its normal functions as follows:

Braking the machine 1. Move the lever (2) to position (E).

2. Remove the lever (2).

3. Adjust washer from position (B) to position (A).

4. Reinstall the lever (2).

5-8

5 - TRANSPORT OPERATIONS

Removing hydraulic short circuit 5. Move the lever (1) to position (F).

6. Remove the lever (1).

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7. Adjust washer from position (B) to position (A).

8. Reinstall the lever (1).

5-9

5 - TRANSPORT OPERATIONS

5-10

6 - WORKING OPERATIONS

6 - WORKING OPERATIONS###_6_### General information

Operating conditions Operating the machine at low temperatures Compacting during winter season depends on the content of fine particles and water in the soil being compacted.

With the temperature dropping below freezing point the soil becomes more solid and harder to compact.

At the temperatures below 0 °C (32 °F) it is possible to compact only dry soils (and stony loose materials), or carry out rapid compaction of non-frozen materials (before soil gets frozen).

Set up the Machine for operation at low temperatures as follows: • Check coolant concentration of engine cooling liquid.

• Exchange engine oil for the one recommended for given external temperature range.

• Use hydraulic oil of viscosity as per the operating temperature.

• Use winter grade diesel fuel.

• Make sure that battery has been charged fully.

Use a fully charged battery with appropriate cold cranking amperage. The Machine can be used at its full capacity only after the operating fluids (engine oil, hydraulic fluid, coolant, etc...) have been heated to their operating temperatures.

Operating the machine at high temperatures and humidity The engine power lowers with the air temperature and moisture increasing.

The relation between the increase in temperature and relative humidity and the loss in power is as follows: • 10 °C (18 °F) increase in temperature at constant humidity leads to 4% drop in engine power.

• 10% increase in relative humidity at constant temperature leads to 2% loss in engine power.

Operating the machine at high altitudes With the altitudes increasing the engine power drops due to lower atmospheric pressure and lower specific weight of intake air.

The machine may be used up to a maximum altitude of 3658 m (12000 ft).

Operating the machine in extremely dusty environment While in very dusty environment: • Reduce the intervals of cleaning and replacing the air filter elements.

• Reduce the replacement intervals of cabin dust filter.

• Reduce the intervals of cleaning the coolers.

NOTICE: The Manufacturer recommends that the cleaning intervals should be brought down to once per week.

6-1

6 - WORKING OPERATIONS

Compaction

Machine travel and reversing including vibration

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Manual (MAN) vibration switching On/Off mode 1. Use the switch (1) to select the drum vibration.

2. Use the switch (2) to select a vibration amplitude.

3. Set a travel speed on the display.

4. Use the travel control (3) to select a direction.

5. Use the switch (4) to select the MAN mode.

Turning On 6. Press the button (5) on the travel control (3) to turn on the vibration.

Turning Off 7. Turn off the vibration by pressing the button (5) on the travel control (3).

8. When the travel control (3) is moved to the brake position (P), the vibration is not active.

NOTE: The MAN mode allows you to turn on the vibration on a standing machine.

6-2

1

6 - WORKING OPERATIONS

Automatic (AUT) vibration switching On/Off mode 1. Use the switch (4) to turn on/off this function.

2. Press button (5) on travel control (3) to switch ON vibration.

3. Vibration will automatically switch ON at travel speed over 1 km/h (0.6 mph) 4. Vibration will automatically switch OFF at travel speed below 1 km/h (0.6 mph).

5. The automatic vibration function remains enabled even after the travel control (3) has been moved through the position 0 and is in the neutral position (N).

Turning Off 1. Turn off the vibration by pressing the button (5) on the travel control (3).

2. You can turn off the vibration by changing the travel control (3) to the brake position (P).

For the maximum permissible slope gradient when driving uphill and across the slope gradient, see figures.

NOTE: The values given are lower depending on adhesive conditions and the machine instantaneous weight.

6-3

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6 - WORKING OPERATIONS

Sprinkling

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1

This feature is used to sprinkle water on the machine drums.

The water level in the tank is displayed on the display (3).

Turning On Switch ON one of two sprinkling pumps via sprinkling pumps selector switch (1).

Set the sprinkling intensity on the display.

The sprinkling pump operation is indicated by the indicator lamp on the display.

Using the watering button (2), it is possible to switch on the additional watering of drums, e.g. before driving on a compacted bitumen surface.

Turning Off Change the sprinkling pump switch (1) to the center position (Position 0).

NOTICE: Use the alternate pumps after every 100 hours of operation to ensure uniform wear.

6-4

6 - WORKING OPERATIONS

Operating with vibration on compacted and hard materials During Machine travel with vibration, the drums may loose contact with the materials being compacted (so called vibro-stroke). This is due to high level of compaction of the background material or travel with vibration on hard materials.

This condition will be apparent to the operator through increased vibration transfer into the machine frame and operator’s controls. This vibration can partly be eliminated through the increased travel speed.

NOTICE: You must not operate the machine in this vibration mode long term. In extreme cases there can be machine damage or the operator can feel discomfort.

6-5

6 - WORKING OPERATIONS

6-6

7 - MAINTENANCE

7 - MAINTENANCE###_7_### General information

General information Environment Before you service the machine and before you dispose of the old fluids, lubricants and filters, always remember the environment.

• Do not pour oil or fluids on the ground, down drains or into containers that can leak.

• Dispose of all old fluids, lubricants and filters in accordance with local regulations.

• Check with your local environmental recycling center or your local dealer for correct information.

Plastic and resin parts • Avoid using gasoline, paraffin, paint thinner, etc., when cleaning plastic, e.g.; console, instrument cluster, monitors and gauges, etc.

• Use only water, mild soap and a soft cloth when you clean these parts.

• Using gasoline, paraffin, paint thinner, etc., will cause color fading, cracking or deformation of the parts being cleaned.

7-1

7 - MAINTENANCE

Tightening torques Confirm regularly that no loosening of bolted connections has occurred.

Use torque wrenches to do all tightening.

Thread size M6 M8 M8x1 M10 M10x1.25 M12 M12x1.25 M14 M14x1.5 M16 M16x1.5 M18 M18x1.5 M20 M20x1.5 M22 M22x1.5 M24 M24x2 M27 M27x2 M30 M30x2

For the screws 8.8 (8G) 10 N·m (7.4 lb ft) 24 N·m (25 lb ft) 19 N·m (14 lb ft) 48 N·m (35.4 lb ft) 38 N·m (28 lb ft) 83 N·m (61.2 lb ft) 66 N·m (48.7 lb ft) 132 N·m (97.3 lb ft) 106 N·m (78.2 lb ft) 200 N·m (147.5 lb ft) 160 N·m (118 lb ft) 275 N·m (202.8 lb ft) 220 N·m (162.2 lb ft) 390 N·m (287.6 lb ft) 312 N·m (230.1 lb ft) 530 N·m (390.9 lb ft) 425 N·m (313.4 lb ft) 675 N·m (497.8 lb ft) 540 N·m (398.2 lb ft) 995 N·m (733.8 lb ft) 795 N·m (586.3 lb ft) 1350 N·m (995.7 lb ft) 1080 N·m (796.6 lb ft)

For the screws 10.9 (10K) 14 N·m (10.3 lb ft) 34 N·m (25 lb ft) 27 N·m (19.9 lb ft) 67 N·m (49.4 lb ft) 54 N·m (39.8 lb ft) 117 N·m (86.2 lb ft) 94 N·m (69.3 lb ft) 185 N·m (136.4 lb ft) 148 N·m (109.1 lb ft) 285 N·m (210.2 lb ft) 228 N·m (168.1 lb ft) 390 N·m (287.6 lb ft) 312 N·m (230.1 lb ft) 550 N·m (405.6 lb ft) 440 N·m (324.5 lb ft) 745 N·m (549.4 lb ft) 590 N·m (435.1 lb ft) 950 N·m (700.6 lb ft) 760 N·m (560.5 lb ft) 1400 N·m (1032.5 lb ft) 1120 N·m (826 lb ft) 1900 N·m (1401.3 lb ft) 1520 N·m (1121 lb ft)

The figures given in the chart are torques at dry thread. These figures do not apply to a lubricated thread.

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Chart showing the torques for cap nuts with sealing O-ring – hoses Wrench size 14 17

Thread size 12x1.5 14x1.5

19

16x1.5

22

18x1.5

24

20x1.5

27

22x1.5

30 32

24x1.5 26x1.5

36

30x2

41

36x2

50

42x2

50

45x2

Hose size 6 8 8 10 10 12 12 14 15 16 18 20 22 25 28 30 35 38 42

Nominal 20 N·m (15 lb ft) 38 N·m (28 lb ft)

Tightening torques Minimum 15 N·m (11 lb ft) 30 N·m (22 lb ft)

Maximum 25 N·m (18 lb ft) 45 N·m (33 lb ft)

45 N·m (33 lb ft)

38 N·m (28 lb ft)

52 N·m (38 lb ft)

51 N·m (38 lb ft)

43 N·m (32 lb ft)

58 N·m (43 lb ft)

58 N·m (43 lb ft)

50 N·m (37 lb ft)

65 N·m (48 lb ft)

74 N·m (55 lb ft)

60 N·m (44 lb ft)

88 N·m (65 lb ft)

74 N·m (55 lb ft) 105 N·m (77 lb ft)

60 N·m (44 lb ft) 85 N·m (63 lb ft)

88 N·m (65 lb ft) 125 N·m (92 lb ft)

135 N·m (100 lb ft)

115 N·m (85 lb ft)

155 N·m (114 lb ft)

166 N·m (122 lb ft) 140 N·m (103 lb ft) 192 N·m (142 lb ft) 240 N·m (177 lb ft) 210 N·m (155 lb ft) 270 N·m (199 lb ft) 290 N·m (214 lb ft) 255 N·m (188 lb ft) 325 N·m (240 lb ft) 330 N·m (243 lb ft) 280 N·m (207 lb ft) 380 N·m (280 lb ft)

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7 - MAINTENANCE

Chart showing the torques for necks with sealing edge, or with flat gasket

Chart showing the torques for plugs with flat gasket

G-M G 1/8 G 1/4 G 3/8 G 1/2 G 3/4 G1 G 11/4 G 11/2

Tightening torque 25 N·m (18 lb ft) 40 N·m (30 lb ft) 95 N·m (70 lb ft) 130 N·m (96 lb ft) 250 N·m (184 lb ft) 400 N·m (295 lb ft) 600 N·m (443 lb ft) 800 N·m (590 lb ft)

G-M G 1/8 G 1/4 G 3/8 G 1/2 G 3/4 G1 G 11/4 G 11/2

Tightening torque 15 N·m (11 lb ft) 33 N·m (24 lb ft) 70 N·m (52 lb ft) 90 N·m (66 lb ft) 150 N·m (111 lb ft) 220 N·m (162 lb ft) 600 N·m (443 lb ft) 800 N·m (590 lb ft)

10 x 1 12 x 1.5 14 x 1.5 16 x 1.5 18 x 1.5 20 x 1.5 22 x 1.5 26 x1.5 27 x 1.5 33 x 1.5 42 x 1.5 48 x 1.5

25 N·m (18 lb ft) 30 N·m (22 lb ft) 50 N·m (37 lb ft) 60 N·m (44 lb ft) 60 N·m (44 lb ft) 140 N·m (103 lb ft) 140 N·m (103 lb ft) 220 N·m (162 lb ft) 250 N·m (184 lb ft) 400 N·m (295 lb ft) 600 N·m (443 lb ft) 800 N·m (590 lb ft)

10 x 1 12 x 1.5 14 x 1.5 16 x 1.5 18 x 1.5 20 x 1.5 22 x 1.5 26 x1.5 27 x 1.5 33 x 1.5 42 x 1.5 48 x 1.5

13 N·m (10 lb ft) 30 N·m (22 lb ft) 40 N·m (30 lb ft) 60 N·m (44 lb ft) 70 N·m (52 lb ft) 90 N·m (66 lb ft) 100 N·m (74 lb ft) 120 N·m (89 lb ft) 150 N·m (111 lb ft) 250 N·m (184 lb ft) 400 N·m (295 lb ft) 500 N·m (369 lb ft)

RAIL14COM0272AC

1

RAIL14COM0273AC

7-4

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7 - MAINTENANCE

Power cut-off switch The power cut-off switch is located inside the left-hand service door toward the front of the unit. The switch is used to shut the battery power off from the machine.

The switch has two positions: position 0 - battery power shut off from unit. position 1 - battery power connected to unit.

RAIL14COM0222AA

1

RAIL16COM0030AA

1

Window washer tank The window washer tank (1) is located in the right rear cab area mounted to the rear console. To fill the tank, remove the cover (2) and fill with TUTELA PROFESSIONAL SC35 fluid.

NOTICE: If water is used, drain the tank when operating in cold weather.

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Hydraulic system care WARNING Avoid injury!

Always engage the parking brake and switch off the engine before working on the machine.

Failure to comply could result in death or serious injury.

W1046A

WARNING Escaping fluid!

Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately.

Failure to comply could result in death or serious injury.

W0178A

The hydraulic reservoir (1) is in the left-hand service door.

The use of approved oil in the hydraulic system is essential for satisfactory system operation. Keep the hydraulic oil in the original closed containers. Clean the top of container before opening and pouring. Use a clean funnel with built in strainer and use extreme care to keep dirt out of the system.

RAIL16COM0111AA

7-6

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7 - MAINTENANCE

Change the hydraulic oil: • As specified in this section.

• Whenever contamination is suspected or, • Every 2000 hours or every two years.

NOTICE: In any instance when the level of oil in the hydraulic oil tank falls below the safe operating level, a hydraulic hose fails, or a hydraulic leak develops, IMMEDIATELY shut off the engine and do not restart until oil levels are restored to operating levels.

NOTICE: If the natural color of the fluid has become black or milky, it is possible that an overheating or water contaminant problem exists. If either of these situations exist, determine the cause and make the necessary repairs then change the oil and filters.

Use only hydraulic oils specified. (Use of unspecified oil will void your warranty.)

NOTICE: It is best not to mix hydraulic oil from different manufacturers. It is far better to mix however, than run your vehicle with a low level of oil. Mixed oil should be completely changed as soon as possible using the recommended oil specified in this section.

Hydraulic system cleanliness Hydraulic system repairs or fluid level change corrections may introduce contaminates into the system. Cleanliness is important. Changing the oil filter and oil at the proper intervals is necessary to maintain quality and a reliable system.

New oil purchased either in bulk or in sealed containers does not meet the cleanliness standards required to insure satisfactory operation and prolonged life of hydrostatic components. Therefore, it is recommended that new oil be pumped into the reservoir through the return filter, center fitting.

The vehicle's filtration system is very effective, and can be utilized to clean the hydraulic oil after the hydraulic system has been opened up for repair or after adding or changing the hydraulic oil. To filter and warm the hydraulic oil, allow the engine to run at high RPM with the vehicle in neutral for a minimum of 20 minutes prior to any operation. Run the machine for at least 1 hour under light load to complete the hydraulic oil filtration. This will minimize the risk of contamination damage.

It is of utmost importance when working on any hydraulic system to keep the components and surrounding area being serviced as clean as possible. Pressure wash all mud, grease, oil, and dirt off the area to be opened up and serviced. Before loosening and removing hydraulic fittings and hoses, spray the immediate area around the fittings with a pressure washer. Aerosol degreaser such as brake cleaner or carburetor cleaner are flammable fluids. If used, avoid hot surfaces or sparks and use only in a well ventilated area. Have threaded plugs and/or caps of the proper size in hand to install immediately.

NOTICE: Only use hydraulic oil filters that meet or exceed the Micron and Beta Ratio specified by CASE CONSTRUCTION Application Equipment. Filters used on CASE CONSTRUCTION Application Equipment machines that fall below the specifications could void the hydraulic system warranty depending on individual circumstances. It is highly recommended to use CASE CONSTRUCTION Application Equipment supplied filters.

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Hydraulic part replacement Whenever repairing/replacing any hydraulic parts follow these guidelines: 1.

Power wash entire machine, especially around area to be worked on.

2.

Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush with aerosol degreaser with fitting backed out 2-3 turns.

3.

Immediately cap or plug any connection that is opened with clean, threaded caps and plugs.

4.

Make necessary repairs.

5.

Fill the hydraulic tank to the correct level.

6.

Start the engine and run in neutral at high RPM.

7.

Cycle any cylinder or motor 5 times through complete stroke, that has been opened, to move any air and debris to the tank.

8.

Allow the engine to run at high RPM with the vehicle in neutral for a minimum of 20 minutes to filter and warm the hydraulic oil prior to any operation.

9.

Run the machine for at least 1 hour under reduced load to complete the hydraulic oil filtration.

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7 - MAINTENANCE

Changing to Organic Acid Technology (OAT) coolant Your unit came equipped with conventional ethylene glycol coolant CNH XHD HEAVY DUTY COOLANT / ANTI-FREEZE. Another coolant, Organic Acid Technology (OAT) coolant solution CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT is available for you unit. This OAT coolant is easily identified by its yellow color. These two coolant types should never be mixed.

The following CNH material specifications must be met for either coolant solution used: • MAT3624 for OAT coolant.

• MAT3620 for conventional coolant.

Depending upon availability, you need to change a machine from conventional coolant to OAT coolant or vice versa, you should follow the “Changing coolant types” procedure below to attain the full benefit of the coolant. You should not mix OAT coolant with conventional coolant.

Mixing OAT coolant with conventional coolant will reduce the effectiveness of OAT coolant.

Changing coolant types To change coolant from OAT coolant to conventional coolant (or vice versa) 1. Empty the engine cooling system by draining the coolant into a suitable container.

2. Fill the system with clean water.

3. Start the engine and run for at least 30 min.

NOTE: Ensure the heating system (if equipped) is activated to circulate fluid through the heater core.

4. Repeat Steps 1 to 3, for a total of two washes.

5. Fill the system with conventional coolant (or OAT coolant).

6. Operate the engine until it is warm. Inspect the machine for leaks.

7. If you are changing to OAT coolant, then attach the label (CNH part number 47488993) to indicate the use of OAT coolant in the cooling system.

47488993

1

Definitions Conventional coolant A coolant that relies on inorganic inhibitors such as silicates, nitrites, and phosphates for corrosion and cavitation protection.

Organic Acid Technology (OAT) coolant A coolant that relies on inhibitors such as organic acid salts for corrosion and cavitation protection.

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Fluids, lubricants and capacities Engine Oil type Oil exchange capacity with filter (approximate.)

Cooling system Coolant type

CASE AKCELA UNITEK NO. 1™ SBL CJ-4 9 L (2.4 US gal) CNH XHD HEAVY DUTY COOLANT / ANTI-FREEZE antifreeze 50% water 50% 23 L (6.1 US gal)

System coolant capacity Hydraulic system Oil type CASE AKCELA NEXPLORE™ FLUID Tank capacity 60 L (15.9 US gal) Fuel Tank capacity 220 L (58.1 US gal) Air conditioning system R134A Refrigerant type Refrigerant capacity 1.2 kg (2.65 lb) Air conditioning compressor Oil type CNH PAG OIL Capacity 0.3 L (0.6 US pt) Steering joint bearings, yoke bearings, steering swivel pins, Suspensions: Grease type TUTELA MULTI -PURPOSE EP GREASE 251H, GR-9 Vibration drum (front and rear) Oil type CASE AKCELA UNITEK 10W-40 Capacity (each drum) 7.5 L (2 US gal) Drum drive reducer Oil type TUTELA HYPOIDE EP GEAR LUBE SAE 80W-90 or TUTELA HYPOIDE EP GEAR LUBE SAE 85W-140 Capacity (each) 2 L (0.53 US gal) Windshield washer tank Fluid type TUTELA PROFESSIONAL SC35 Capacity 2.75 L (0.72 US gal) Drum watering tank Fluid type Water Tank capacity 840 L (222 US gal) Drum cooling liquid Fluid type Mixture of: 23.0 L (6.1 US gal) of water 51 kg (112 lb) of calcium chloride Capacity (each drum) 100 L (26.4 US gal)

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7 - MAINTENANCE

Recommended engine oil for operating temperature ranges CASE CONSTRUCTION prefers the use of CASE AKCELA UNITEK NO. 1™ SBL CJ-4 engine oil in your engine.

This multi-viscosity oil will lubricate your engine correctly under all operating conditions. CASE AKCELA UNITEK NO. 1™ SBL CJ-4 engine oil has a maximum service change interval of 600 h.

You may also use CASE AKCELA NO. 1™ ENGINE OIL in your engine. CASE AKCELA NO. 1™ ENGINE OIL has a maximum service change interval of 400 h.

You may use other engine oils if the engine oils meet API CJ-4 performance requirements. The maximum service change interval for these engine oils is 300 h.

CASE CONSTRUCTION engine oils exceed API CJ-4 performance requirements.

See the following chart for recommended viscosity at varying ambient air temperature ranges.

NOTE: Do not put performance additives or other oil additive products in the engine crankcase. CASE CONSTRUCTION develops the oil change intervals given in this manual from tests with CASE CONSTRUCTION lubricants.

For machines with Tier 4B (final) engines

(H) (H)

0W-40 CJ-4 UNITEK to CNH MAT3521 0W-40 API CJ-4* (H) (H)

10W-40 CJ-4 UNITEK to CNH MAT3521 10W-40 API CJ-4* (H) (H)

-40 °C -40 °F

-30 °C -22 °F

-20 °C -4 °F

-10 °C 14 °F

15W-40 CJ-4 to CNH MAT3522** 15W-40* API CJ-4* 0 °C 32 °F

10 °C 50 °F

20 °C 68 °F

30 °C 86 °F

40 °C 104 °F

50 °C 122 °F

(H) CASE CONSTRUCTION recommends the use of an engine oil pan heater or coolant block heater in this range. * Maximum engine oil service change interval is 300 h **Maximum engine oil service change interval is 400 h

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7 - MAINTENANCE

General specification - Diesel fuel Only use diesel fuel that conforms to North American standard ASTM D975 Grade No. 2-D S15 or equivalent in your engine. Do not use any other low grade diesel fuel.

NOTE: When operating the machine in very cold climates, the use of winter blended fuel is permitted for a short period of time. See your fuel supplier for winter fuel requirements in your area.

NOTICE: Use of other low grade diesel fuels will result in loss of engine power, high fuel consumption, and damage to the exhaust aftertreatment system (if equipped).

Fuel conditioner Diesel fuel conditioner is available from your CASE CONSTRUCTION dealer. Instructions for the use of the fuel conditioner is on the container.

The use of diesel fuel conditioner will: • Clean fuel injectors, valves, and manifolds for increased service life

• Separate moisture from the fuel • Stabilize fuel in storage NOTICE: Use only CASE CONSTRUCTION approved biocide additives to prevent damage to the exhaust aftertreatment system (if equipped).

• Disperse insoluble gummy deposits that form in the fuel system

7-12

7 - MAINTENANCE

General specification - Biodiesel fuels Biodiesel usage in CASE CONSTRUCTION products

suppliers are allowed to use up to 5 % biodiesel fuel (B5) to supply the network.

Introduction to Fatty Acid Methyl Ester (FAME) biodiesel

• United States Biodiesel Fuel Specification ASTM D7467 provides specifications for diesel and biodiesel blends from B5 to B20.

FAME biodiesel, called biodiesel fuel in the following section, consists of a family of fuels derived from vegetable oils treated with methyl esters.

There are two main biodiesel fuel types: Rapeseed Methyl Ester (RME) and Soybean Methyl Ester (SME).

RME is a blend of rapeseed and sunflower methyl ester, and is the preferred crop in Europe. SME is the preferred crop in the United States.

Biodiesel fuel is a renewable alternative fuel source. Its use and development is promoted worldwide, especially in Europe and in the United States.

NOTICE: Your emissions control system is compatible with up to 5 % biodiesel fuel (B5). Be aware that the use of biodiesel fuel that does not comply with the standards mentioned in this section could lead to severe damage to the engine, fuel system or aftertreatment system of your machine. The use of non-approved fuels may void CASE CONSTRUCTION Warranty coverage.

Biodiesel can be used to run Tier 4b diesel engines only when blended with standard diesel fuel: • B5: indicates the blend of 5 % biodiesel and 95 % diesel fuels.

• B20: indicates the blend of 20 % biodiesel and 80 % diesel fuels. Do not use.

Biodiesel fuel has several positive features in comparison with diesel fuel: • Biodiesel fuel adds lubricity to the fuel, which is beneficial in many circumstances, particularly as sulfur and aromatics are removed from the fuel.

• Biodiesel has a greater cetane number and burns cleaner.

• Biodiesel produces less particulate matter and reduces smoke emissions.

• Biodiesel is fully biodegradable and non-toxic.

Pure biodiesel blend stock (B100) specification is covered by the following requirements: • ASTM D6751 - Standard specification for biodiesel fuel blend stock (B100) for middle distillate fuels.

NOTE: ASTM D6751 specification has been updated to improve the quality of biodiesel in the market place.

Before raw oil can be converted into usable biodiesel fuel, it must undergo transesterification to remove glycerides. During the transesterification process, the oil reacts with an alcohol to separate the glycerine from the fat or vegetable oil. This process leaves behind two products: methyl ester (the chemical name for biodiesel) and glycerine (a byproduct usually sold for use in soaps or other products).

NOTICE: Biodiesel fuels approved for use in the CASE CONSTRUCTION equipment must be transesterified and comply with the latest North America Standard ASTM D6751.

NOTICE: Cold Pressed Biodiesel, Cold Pressed Oil, Straight Vegetable Oil (SVO), or more generally unrefined vegetable oils used as motor fuel, are fuels that are normally made from Rapeseed oil or similar high oil content crops. These kinds of fuel are not transesterified, so they do not fulfil the ASTM D6751 requirements. There is no recognized quality standard available for these types of fuel. Therefore the use of Cold Pressed Biodiesel, Cold Pressed Oil, Straight Vegetable Oil (SVO), or more generally unrefined vegetable oils used as motor fuel are NOT APPROVED at any blend in any CASE CONSTRUCTION product.

NOTICE: Any engine and fuel injection equipment fitted to a CASE CONSTRUCTION vehicle found to have run with any blend of NON-APPROVED fuel (fuel not fulfilling the specification described in the requirement ASTM D6751) will no longer be covered for Warranty by CASE CONSTRUCTION.

Biodiesel fuel usage conditions

Diesel and biodiesel fuel specifications Tier 4b diesel fuel specifications are covered by the following: • ASTM D975, Standard Specification for Diesel Fuel Oils. (15 ppm sulfur maximum.)

You must stringently follow the biodiesel fuel usage conditions. Incorrect application of the biodiesel fuel usage conditions could lead to severe damage to the engine, fuel injection equipment and aftertreatment system.

Biodiesel blends are covered by:

The main concerns related to operation with biodiesel fuels are:

• United States Diesel Fuel Specification ASTM D975 allows up to 5 % biodiesel since 2009. United States fuel

• Filters and injector blockage caused by poor fuel quality.

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7 - MAINTENANCE

• Wear and corrosion of internal components due to water content, which affects lubricity.

• Deterioration of some rubber sealing compounds in the fuel system.

• Biodiesel oxidation, which can lead to the formation of deposits that can harm the fuel injection system.

NOTICE: Any problem in the engine fuel injection equipment associated with non-compliance to the following conditions for biodiesel fuel handling and maintenance will not be covered for Warranty by CASE CONSTRUCTION. Purchase biodiesel fuel from a trusted supplier who understands the product and maintains acceptable fuel quality. The National Biodiesel Board awards BQ-9000® accreditation to biodiesel marketers and producers that meet strict quality and consistency standards. Biodiesel users in North America are strongly encouraged to purchase biodiesel blends from the BQ-9000® Certified Marketers and sourced from the BQ-9000® Accredited Producers found on the BQ-9000® website.

The use of biodiesel blends up to B5 will not void the CASE CONSTRUCTION warranty as long as the following conditions for biodiesel fuel handling and maintenance are stringently followed: Biodiesel fuel must be pre-blended by the supplier. Mixing biodiesel fuels on-site can result in an incorrect mixture that could damage the engine and/or fuel system.

NOTICE: CASE CONSTRUCTION may void your warranty if the problem is associated with poor fuel quality due to improper blending. It is the responsibility of the fuel supplier and/or yourself to ensure the right type of fuel and blend is delivered and used.

Storage The machine should not be stored for more than 6 months with biodiesel in the fuel system. For longer storage time, it is strongly suggested that only regular #2 diesel fuel is used.

NOTE: If storage for longer than 6 months is necessary, the engine must be run on regular #2 diesel for a minimum of 20 hours to flush the biodiesel fuel out of the fuel system prior to storage.

Biodiesel is highly hygroscopic and tends to collect water more than diesel fuel. This increases the risk of algae and bacteria growth which can cause severe damage to the fuel injection system. Keep the machine fuel tanks and on-site storage tanks as full as possible to limit the amount of air and water vapors inside the tank. Drain water from the tanks at least once a week.

NOTICE: Use only CASE CONSTRUCTION approved biocide additives on Tier 4b engines with an exhaust aftertreatment system.

Limited B10 biodiesel approval CASE CONSTRUCTION approves the use of up to B10 on Tier 4b engines only in Minnesota (or other States & Provinces) where the state legislation mandates its usage during the months of April to September only and the state legislation mandates strict compliance of the B10 to specification ASTM D7467. The B10 must consist of a blend of S15 #2D Diesel Fuel per ASTM D975 and B100 blend stock per ASTM D6751 only.

7-14

7 - MAINTENANCE

Assisted starting (jump-starting) DANGER Explosion hazard!

When jump-starting the machine, connect and disconnect the jumper cables as instructed in this manual. Make sure no persons are near the connecting points before starting the engine. Start the engine from the operator’s seat.

Failure to comply will result in death or serious injury.

D0128B

WARNING Explosion hazard!

Batteries emit explosive gases. Always ventilate when using in an enclosed area or when charging.

Keep the battery away from sparks, open flames, and other ignition sources.

Failure to comply could result in death or serious injury.

W0369A

RAIL14COM0302FA

1

NOTICE: The booster battery should be a 24 V battery.

Follow the procedure to connect te booster battery to the machine battery.

3. Connect one end of the negative jumper cable (Black) to (–) terminal of the booster battery (3).

1. Connect one end of the positive jumper cable (Red) to (+) terminal of the discharged battery (1).

4. Connect the other end of the negative jumper cable to the vehicle frame (4) or the engine block.

2. Connect the other end of the positive jumper cable to (+) terminal of the booster battery (2).

NOTICE: After starting the engine, remove the jumper cables in reverse order.

NOTICE: Do not connect (-) pole cable to (-) pole of discharged battery of the Machine being started! There is risk of strong sparking in course of starting followed by explosion of battery-generated gas.

NOTICE: Make sure the non-insulated parts of the battery jump cable clamps do NOT contact each other!

7-15

7 - MAINTENANCE

NOTICE: Make sure the jump cable connected to (+) pole of the battery does NOT come into contact with electrically conductive parts of the Machine - danger of short circuit!

NOTICE: Do NOT lean over the battery - risk of electrolyte burn!

NOTICE: Rule out any presence of flammable sources (open flame, burning cigarettes, etc.)

NOTICE: Do NOT confirm voltage presence in a wire through sparking via Machine frame!

7-16

7 - MAINTENANCE

Lubrication and service schedule This Manual includes only the basic engine information, others are given in the Engine Operaion and Maintenance Manual which is part of documentation supplied with the Machine.

Carry out the inspection of the Machine located on flat, solid surface. Chock the drums to avoid the machine from moving. Switch off the engine, remove the key from ignition switch. Shut off the battery power with the power cut-off switch (unless otherwise required).

RAIL14COM0313FC

1

Engine oil

Grease

Hydraulic oil

Transmission oil

Top up

Change fluid

Carry out lubrication and maintenance in regularly repeated intervals as per the everyday data reading of the hourmeter (1).

RAIL14COM0306FA

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7 - MAINTENANCE

Maintenance planning

Maintenance chart Change fluid Drain fluid Level make up Cleaning Check

Grease Replace Test Bleed Adjust

Maintenance action

Page no.

Every 10 hours or daily x Engine oil level x Engine coolant level x Engines leaks x Air filter dust valve x Cooling fan x Fuel tank level x Hydraulic oil level x Water tank x Controls and alarms x Drum drive reducer gearbox x Air-conditioning compressor drive belt (if equipped) x Exhaust system leaks x Engine fuel system pre-filter x Radiator cooler fins First 200 hours x Drum drive reducer gearbox Every 250 hours or every 3 months x Water filter x Lubrication points First 500 hours x Vibration system oil Every 500 hours or every 6 months x Engine accessory drive belt x Engine oil and filter x Air intake and cooling hoses x Air filter sensor x Engine coolant concentration level x Wiring x Air-conditioning refrigerant level (if equipped) x Cab ventilation air filters (if equipped) x Engine fuel filter and pre-filter x Engine air filter Every 1000 hours or annually x Engine cooling system x Battery x Engine belts x Drum drive reducer gearbox x Vibration system oil x Rubber isolation mounts x Water tank x Water / Oil / Intercooler Radiator x Engine x Engine and machine control modules/control units x Air-conditioning compressor drive belt (if equipped) x Air-conditioning compressor mounting (if equipped) 7-18

7-20 7-21 7-22 7-22 7-22 7-23 7-24 7-25 7-26 7-28 7-28 7-29 7-29 7-29 7-30 7-31 7-33 7-35 7-36 7-37 7-39 7-40 7-41 7-41 7-42 7-42 7-43 7-46 7-49 7-50 7-52 7-54 7-54 7-55 7-57 7-58 7-59 7-59 7-60 7-61

7 - MAINTENANCE

Change fluid Drain fluid Level make up Cleaning Check

Grease Replace Test Bleed Adjust

Maintenance action Hydraulic oil and filter Engine coolant Bleeding the fuel system Water / Oil / Intercooler Radiator Scrapers Machine cleaning Loose hardware Drain the water tank

Page no.

Every 2000 hours or 2 years x x As required

7-62 7-66 x

x x x x

7-19

7-69 7-69 x 7-70 7-71 7-72 7-73

7 - MAINTENANCE

Every 10 hours or daily

Engine oil level Engine oil capacity: 9 L (2.4 US gal) 1. Pull out oil dipstick (1) and wipe it clean.

2. Push the dip stick (1) back down fully, pull out again and read the oil level.

NOTE: Turn off the engine and wait for 5 minutes to let the oil drain to the sump before checking the oil level.

3. If necessary, remove filler port (2) and add oil.

NOTICE: Do NOT run the engine unless there is correct oil level in the engine. Maintain the level between the division lines stamped on the dipstick.

RAIL14COM0217AA

1

RAIL14COM0202AA

2

4. Low division mark MIN (minimum) shows lowest possible oil level, high division mark MAX (maximum) shows the highest level.

5. The amount of oil between MIN and MAX marks is 1.5 L (0.4 US gal) 6. Following the refill, please wait for 5 minutes until oil descends into the sump, then check the level.

Oil specification Use CASE AKCELA UNITEK NO. 1™ SBL CJ-4 , MAT3521 engine oil or an oil meeting the following specification: • API CJ-4 • ACEA E9 NOTE: A higher quality oil is accepted.

NOTICE: Refer to 7-11 for oil viscosity and temperature ranges.

7-20

7 - MAINTENANCE

Engine coolant level WARNING Hot liquid under pressure!

Scalding can result from fast removal of the radiator cap. Check and service the engine cooling system according to the maintenance instructions in this manual.

Failure to comply could result in death or serious injury.

W0163A

Capacity: 23 L (6.1 US gal) NOTICE: Wait to remove the filler plug only after engine coolant temperature drops below 50 °C (120 °F).

NOTICE: Do NOT use any additives to repair cooling system leaking into the engine coolant!

NOTICE: Do NOT refill cold coolant in hot engine. This will damage the engine castings.

1. Before starting the engine, visually inspect the level through the gauge (2).

2. If required, top up the coolant mixture through filler neck (1).

3. Keep level between “MIN” and “MAX” markings.

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4. In case of high coolant loss, find out any cooling system leakage and rectify the problem.

Coolant specification Use CNH XHD HEAVY DUTY COOLANT / ANTI-FREEZE or a coolant meeting the following specification: • ASTM D6210 Type 1-FF NOTE: CASE AKCELA PREMIUM ANTI-FREEZE can also be used.

The coolant is a water and antifreeze mixture containing: • 50% water • 50% antifreeze The quality of the water should not exceed following limits: • Total hardness: 0.03% • Chlorides: 0.01% • Sulfates: 0.01%

7-21

7 - MAINTENANCE

Engines leaks 1. Visually check the engine and engine compartment for any oil leaks.

2. If there are any oil leaks, find the cause for the leak and rectify.

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Air filter dust valve 1. To clean the air filter dust valve (1), press and remove any dust trapped.

NOTE: Any dust trapped in the dust valve (1) will automatically be emptied when the engine is running.

NOTICE: Do NOT operate the Machine with a damaged dust valve (1). If air filter dust valve is damaged, replace it with new one.

Cooling fan 1. Visually inspect the fan. In case of any damages (e.g. missing parts of material, cracks, shape changes, etc.), replace the fan.

7-22

7 - MAINTENANCE

Fuel tank level WARNING Fuel vapors are explosive and flammable.

Do not smoke while handling fuel. Keep fuel away from flames or sparks. Shut off engine and remove key before servicing. Always work in a well-ventilated area. Clean up spilled fuel immediately.

Failure to comply could result in death or serious injury.

W0904A

Fuel tank capacity: 220 L (58.1 US gal) Check the fuel quantity on the display. If necessary, refill as follows:

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1. Clean tank filler cap (1) and filler neck (2).

2. Unlock and remove the cap (1).

3. Refill the tank via the strainer up to the bottom edge of filler neck.

NOTICE: Do not fill the tank completely. space in the tank for expansion.

Leave some

7-23

7 - MAINTENANCE

Hydraulic oil level Hydraulic systems capacity: 60 L (15.9 US gal) 1. Open the right door.

2. Check oil level through the gauge (1).

3. Use the filler neck (2) to refill the system.

NOTICE: Upon higher loss of oil, find out the cause of hydraulic system leaking (leaks through hose screw joints, screwed fitting of hydroelectric generators or of hydraulic motors, etc.), and repair the defects.

RAIL16COM0111AA

Hydraulic oil specifications: NOTICE: Oil quality and cleanliness are of utmost importance for the reliability and life of the hydraulic system. Deviation from the prescribed oil specification may lead to severe damage and void warranty.

Use CASE AKCELA NEXPLORE™ FLUID, MAT 3525 or an oil meeting the following specification: • API GL-4 • ISO VG-32/46 • SAE 10W30 • DIN 51524 PART 3 HV46 • ISO VG-46 or use , TUTELA HYDROSYSTEM AW 46 , MAT 3508 or an oil meeting the following specification: • DIN 51524 PART 3 HV46 • ISO VG-46 The hydraulic system is factory‐filled with, CASE AKCELA NEXPLORE™ FLUID, MAT 3525 hydraulic oil.

This is an oil with a high viscosity index, which means that the oil remains fluid at low temperatures.

Only for machine that operate in hot environments, CASE AKCELA AW HYDRAULIC FLUID 68 HV ( MAT 3508) hydraulic oil or an oil meeting the following specification is recommended: • DIN 51524 PART 3 HV68 • ISO VG-68 NOTICE: Consult your dealer for the correct oil specification to be used.

7-24

1

7 - MAINTENANCE

Water tank Capacity: 840 L (222 US gal) 1. Check the water quantity on the display and refill if need.

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2. Open the cap (1) and refill with clean water via the strainer (2).

NOTICE: Before winter period, refer to 7-73 and drain water from the water tank and sprinkling system.

7-25

7 - MAINTENANCE

Controls and alarms 1. Turn the ignition key to position I.

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2. The brake indicator, charging indicator and pre-heating indicator lamps will light up on the display.

3. Test the functions of the following controls: 1.

Warning horn button

2.

Turn indicators switch

3.

Hazard light switch

4.

Headlight switch (optional)

5.

Rear lights switch (optional)

6.

Additional lights switch (optional)

7.

Warning beacon switch (optional)

7-26

7 - MAINTENANCE

WARNING Hazard to bystanders!

Always sound the horn before starting the machine. Make sure the work area is clear of other persons, domestic animals, tools, etc. before you operate the machine. Never allow anyone in the work area during machine operation.

Failure to comply could result in death or serious injury.

W0304A

4. Start the engine turning key to position II.

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5. Verify that the charging indicator lamp (1) goes out after the unit is started.

6. Move the travel control to either the forward or reverse position.

7. After the machine starts moving, the brake indicator (1) lamp must go out.

Emergency brake function 1. Check in front of and behind the machine to make sure no person is present.

2. Sound the horn to indicate the engine starting.

3. Start the engine.

4. Start moving the machine at low speed.

5. Press the emergency brake button (1).

6. The machine will stop, the parking brake will be enabled and the engine will shutdown.

7. The brake indicator lamp lights up on the display.

8. Move the travel control (2) to the brake position (P).

9. Turn the ignition key to the position 0.

10. Now you can start the engine again.

7-27

7 - MAINTENANCE

Drum drive reducer gearbox 1. Check the drum drive reducer gearboxes visually for oil leaks.

2. If there are any oil leaks, find the cause for the leak and rectify.

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Air-conditioning compressor drive belt (if equipped) 1. Make visual belt inspection, monitor any of its damage.

Cracks perpendicular to the belt width are not considered a damage.

NOTICE: When longitudinal cracks occur on the belt, belt edges are shattered, or extracted parts of material in the belt, the belt must be replaced.

7-28

7 - MAINTENANCE

Exhaust system leaks 1. Check clamps and pipings of the exhaust system.

2. If there are any leaks, find the cause for the leak and rectify.

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1

Engine fuel system pre-filter WARNING Fire hazard!

When handling diesel fuel, observe the following precautions: 1. Do not smoke.

2. Never fill the tank when the engine is running.

3. Wipe up spilled fuel immediately.

Failure to comply could result in death or serious injury.

W0099A

1. Turn off the engine.

2. Use a suitable container of adequate volume to collect the drained fuel.

3. Disconnect the connector (1).

4. Loosen the fitting (2).

5. Drain the fuel until clean fuel flows out.

6. Tighten the fitting (2). Tightening torque 1.3 - 1.9 N·m (0.96 - 1.4 lb ft).

7. Connect the connector (1).

NOTICE: NEVER drain the pre-filter when the engine is running.

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Radiator cooler fins Check the radiator cooler fins for clogging. If the fins are clogged, clean them by blowing out the coolers with compressed air, steam or hot water) as explained in Page 7-69.

7-29

1

7 - MAINTENANCE

First 200 hours

Drum drive reducer gearbox Capacity: 2 L (0.53 US gal) 1. Clean the area around plugs.

2. Place a suitable container under the drain plug (3) to collect the drained oil.

NOTE: Approximate drain volume would be 2 L (0.5 US gal).

3. Remove the plugs (1), (2) and (3) and let oil drain.

NOTICE: Drain the oil when the gearbox is still warm, the oil will flow more easily.

4. Check the seals of the plugs for any damage. Replace if necessary.

5. Mount the drain plug (3) after the oil is drained completely.

6. Refill the oil through the filling plug (1).

7. Check oil level in the checking opening (2). The oil level must reach the lower edge of the opening or slightly flow out.

8. Reinstall the plugs (1) and (2).

9. Top up as necessary.

Oil specification • Use TUTELA HYPOIDE EP GEAR LUBE SAE 80W-90 ( MAT-3511) for outdoor temperatures between -10 30 °C (14 - 86 °F) • Use TUTELA HYPOIDE EP GEAR LUBE SAE 85W-140 ( MAT-3511) for outdoor temperatures between 20 45 °C (68 - 113 °F) • Or an oil confirming to the following standards: ○ API GL-5 ○ MIL-L-2105 C

7-30

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1

7 - MAINTENANCE

Every 250 hours or every 3 months

Water filter 1. Close water supply through the valve (1).

2. Remove sprinkler filter housing (2), replace the strainer (3) and clean it.

3. Check the O-ring (4). Replace if damaged.

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4. Remove the sprinkler nozzle assemblies (5).

5. Remove and clean sprinkler strainers (6).

6. Flush the sprinkler line.

7. Reinstall sprinkler nozzle assemblies (5). Hand tighten the nut (7).

7-31

7 - MAINTENANCE

8. Remove valves and clean diaphragms (8).

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9. Remove the sprinkler nozzle assembly (9).

NOTE: Optional edger shown.

10. Remove and clean the sprinkler strainers (10).

11. Reinstall sprinkler nozzle assemblies (9). tighten the nut.

Hand

7-32

7 - MAINTENANCE

Lubrication points 1. Take off the caps on the greasing points.

2. Pump the new grease into the grease fittings with a high-pressure grease gun until the old grease starts flowing out.

3. Reinstall the greasing point caps.

Steering cylinder Number of greasing points: 4

7-33

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3

7 - MAINTENANCE

Steering joint Number of greasing points: 2

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5

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Edge cutter cylinder (if equipped) Number of greasing points: 2

Cab door hinges Number of greasing points: 4

Grease specifications Use TUTELA MULTI -PURPOSE EP GREASE 251H, GR-9 ( MAT 3550) or a grease which meets the following standard: • NLGI 2 NOTE: CASE AKCELA 251H EP MULTI-PURPOSE GREASE can also be used.

7-34

7 - MAINTENANCE

First 500 hours

Vibration system oil Vibration drum capacity: 7.5 L (2 US gal) per drum

Oil draining 1. Clean the area around the plug (1).

2. Position the machine so that the plug (1) is in the lowest position.

3. Remove the plug and drain the oil in a suitable container.

NOTE: Approximate drained volume: 10.5 L (2.8 US gal) NOTICE: Drain the oil when the gearbox is still warm, the oil will flow more easily.

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Oil filling 4. Position the machine so that the plug (1) is in the highest position.

5. Fill the oil through the filler plug.

6. Check the oil level in the inspection hole (2).

7. The oil level must reach the lower edge of the hole or flow out slightly.

8. Reinstall the plugs and replace the plug seals.

9. Repeat the above steps on the rear drum.

Oil specification NOTE: Engine oil is used as the vibration drum operating fluid.

Use CASE AKCELA UNITEK 10W-40 Engine oil SAE 10W40, MAT3521 engine oil or an oil meeting the following specification: • API CJ-4 • ACEA E9 NOTE: A higher quality oil is accepted.

NOTICE: For machines operating in cold regions, refer to Page 7-11 for recommended engine oil for operating temperature ranges.

7-35

7 - MAINTENANCE

Every 500 hours or every 6 months

Engine accessory drive belt 1. With the unit stopped on a hard level surface, place the travel control in the park brake position.

2. Shut the engine off and remove the key from the unit.

3. Remove the engine guards (1).

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4. Visually check the belt (2) for sign of wear and damages. Cracks running perpendicular to the belt are not considered damage.

5. Replace the belt if there are longitudinal cracks, shattered edges or protruding materials on the belt.

6. Reinstall the engine guards.

7-36

7 - MAINTENANCE

Engine oil and filter WARNING Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in death or serious injury.

W0330B

Engine oil capacity: 9 L (2.38 US gal) 1. Use a suitable container of adequate capacity to collect the drained engine oil.

NOTE: The volume of drained engine oil will be approximately 9 L (2.4 US gal).

2. Remove drain plug (1) and let the oil flow out.

NOTICE: Drain the oil when the oil is still warm, the oil will flow more easily.

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3. Open the right-hand side door.

4. Remove the filter (2).

5. Clean the filter gasket seat with a lint free cloth.

6. Apply a thin layer of clean oil on the seal (3) of the new filter cartridge (4).

NOTICE: DO NOT fill the new filter with oil before installing it.

7-37

7 - MAINTENANCE

7. Manually tighten the filter cartridge (4) until the seal (3) touches the support. Tighten the filter by hand another 1/2 to 3/4 turn.

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8. Check for the condition of the drain plug gasket, replace if necessary.

9. Check and clean the threads and gasket seating.

10. Reinstall the plug (1).

NOTICE: Collect the drained oil in a suitable container and dispose off as per the local regulations.

11. Use filler port (5) to fill the engine with clean engine oil.

1.

Fill up to the dipstick’s (6) top division mark.

2.

When oil is changed, start the engine and let it run at higher idle rpm for 2 - 3 min.

3.

Stop the engine and wait for 3 min until oil drains into the sump and check the proper oil level.

NOTE: For this replacement, it is essential that an original spare cartridge is used.

NOTICE: Do not overtighten the filter, the thread and gasket may get damaged.

Oil specification Use CASE AKCELA UNITEK NO. 1™ SBL CJ-4 , MAT3521 engine oil or an oil meeting the following specification: • API CJ-4 • ACEA E9 NOTE: A higher quality oil is accepted.

NOTICE: Refer to 7-11 for oil viscosity and temperature ranges.

7-38

7 - MAINTENANCE

Air intake and cooling hoses 1. Check the hoses (1) and clamps (2).

2. Replace the damaged clamps (2) or hoses (1) before operating the machine.

7-39

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7 - MAINTENANCE

Air filter sensor 1. Park the unit on a hard level surface.

2. Place blocks in front of both the front and rear drums to prevent movement.

3. Set the travel control lever (1) to the neutral position (N). This will set the engine speed to idling rpm.

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4. Cover the air suction hole.

NOTICE: Do not use objects like thin paper to cover it, paper may get sucked in and clog the intake.

5. Once covered, the indicator lamp for air filter clogged should come On in the display.

6. If the indicator does not go ON, check the vacuum switch (1), contacts and feeder cables (2).

7-40

7 - MAINTENANCE

Engine coolant concentration level 1. Check the concentration via a refractometer.

2. If the concentration for -36 °C (-33 °F) has not been measured, adjust the concentration of 50% water and 50% antifreeze by adding more antifreeze into the cooling system.

SS12D505

Wiring Check for any damage to cables, connectors, protective hoses and their fastening, especially if in the vicinity of hot surfaces and moving parts of the machine including the engine. Replace damaged parts. Use only original spare parts.

7-41

1

7 - MAINTENANCE

Air-conditioning refrigerant level (if equipped) WARNING Maintenance hazard!

Never try to service the air-conditioning system yourself. Contact your dealer for service.

Failure to comply could result in death or serious injury.

W0268A

1. If the air conditioning is not functioning correctly, contact your CASE CONSTRUCTION dealer for service.

Cab ventilation air filters (if equipped) 1. Remove the filter element by pulling it out of the console.

2. Gently tap the element to clean.

3. If the element is damaged, replace with a new element.

NOTE: When the unit is used in a dusty environment, clean element monthly.

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7-42

1

7 - MAINTENANCE

Engine fuel filter and pre-filter WARNING Fire hazard!

When handling diesel fuel, observe the following precautions: 1. Do not smoke.

2. Never fill the tank when the engine is running.

3. Wipe up spilled fuel immediately.

Failure to comply could result in death or serious injury.

W0099A

Fuel filter 1. Close the fuel tank valves (1).

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2. Clean the outside of the fuel filter (2).

3. Use a suitable container of adequate volume to collect the drained fuel.

4. Remove the filter (2).

5. Clean the seal surface of filter holder.

6. Apply a thin layer of clean oil on the seal (3) of the new filter cartridge (4).

NOTICE: DO NOT fill the new filter with fuel before installing it.

7-43

7 - MAINTENANCE

7. Manually tighten the filter cartridge (4) until the seal (3) touches the support. Tighten the filter by hand another 1/2 to 3/4 turn.

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7-44

4

7 - MAINTENANCE

Fuel pre-filter 1. Disconnect the connector (1).

2. Clean the fuel filter (2).

3. Use a suitable container of adequate volume to collect the drained fuel.

4. Remove the filter (2).

5. Clean the seal surface of the filter holder.

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SS12C389

6

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6. Apply a thin layer of clean oil on the seal (3) of the new filter cartridge (4).

7. Manually tighten the filter cartridge (4) until the seal (3) touches the support. Tighten the filter by hand another 1/2 to 3/4 turn.

8. Connect the sensor connector.

9. Open fuel tank valves (1).

10. See Page 7-69 and bleed the fuel system.

11. Start the engine and check for any fuel leaks in the filter area. Retighten the filter in case of leak in the filer area.

NOTICE: Do not overtighten the filter, the thread and gasket may get damaged.

7-45

7 - MAINTENANCE

Engine air filter CAUTION Inhalation hazard!

Wear a dust mask to clean the filter element.

Failure to comply could result in minor or moderate injury.

C0032A

The air filter comprises the main element and safety element. The proper maintenance of air filter and of the entire inlet piping, the rubber parts in particular, will ensure maximal protection of the engine against dust effects, and prolong the life of the element and its efficiency.

The inherent sign of fouled filter is the exhaust pipe that smokes, higher fuel consumption, output loss and engine temperature increased.

Observe the following precautions when replacing a filter: 1.

NEVER use damaged elements.

2.

Do NOT use unapproved filter elements.

3.

Do NOT remove the elements just for checking purposes.

4.

Do NOT leave the filter cover opened longer than necessarily required.

5.

NEVER operate the Machine with filter cover damaged.

6.

Always clean the inner bodies of the cleaner in a way to avoid dust penetrating inside the engine feed piping.

7.

Clean the seating faces for gasket in the cleaner body.

8.

Examine the dust traces in the element removed, any traces would be an indication of its leakage in the filter body.

9.

Make sure the gasket on the new element is flexible.

10. Replace the main element whenever the air filter clogged indicator (1) goes ON in the display.

7-46

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1

7 - MAINTENANCE

Filter element replacement: 1. Remove the filter cover (2) from the filter housing (3).

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2. Remove the main filter element (4) from the filter housing.

3. Remove the safety element (5) from the filter housing.

Check the safety element for excess dirt or damage and replace if necessary.

NOTE: The safety element must be changed on every third replacement of the main filter or when the primary has failed and the safety element is dirty.

4. Clean the inner surface of the filter housing taking care to avoid any dust penetration into the inner feed pipe (6).

7-47

7 - MAINTENANCE

5. Reinstall the inspected or install a new safety element (5) into the filter housing making sure the element is properly seated.

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6

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6. Install a new main filter element (4) into the filter housing making sure the element is properly seated.

7. Install the filter cover (2) on the filter housing (3).

8. Clean the air filter vacuum valve (7) and reinstall.

NOTICE: Replace the vacuum filter valve (7) if it is damaged.

7-48

7 - MAINTENANCE

Every 1000 hours or annually

Engine cooling system 1. Check the cooling circuit leaks, tighten the loose connections if necessary.

2. Make sure that no hoses are damaged and no clamps are missing.

3. Check the cooler fins for clogging. If the fins are clogged, clean them by blowing out the coolers with compressed air, steam or hot water) as explained in Page 7-58.

7-49

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7 - MAINTENANCE

Battery Follow the below safety precautions when working with Batteries: 1. Use rubber gloves and safety glasses when working with the battery.

2. Protect your skin with proper clothing against being stained by electrolyte.

3. Upon eye contact with electrolyte immediately flush eyes with large amounts of water for at least a couple of minutes. Get prompt medical attention.

4. Upon ingestion of electrolyte, drink a large amount of milk, water, or solution of calcined magnesia in water.

5. Upon skin contact with electrolyte, remove contaminated clothing, shoes, and wash affected spots as soon as possible with soap and water. Get prompt medical attention.

6. Do not eat, drink, smoke, while working near the battery.

7. After finishing the work, wash your hands and your face thoroughly with water and soap!

8. Keep the battery dry and clean.

9. Recharge the undercharged battery.

10. Recharge the battery off of the Machine.

11. Never disconnect the battery with the engine is running.

12. Follow the battery manufacturer’s manual when working with the battery!

13. Disconnect the battery during its repair, or when handling the wires and electric devices within the wiring circuit to avoid any short circuit.

14. To disconnect the battery you must first disconnect (–) pole of the cable. To connect, first connect (+) pole.

15. Never make direct conductive connection between the battery’s both poles, short circuit will occur with the risk of battery explosion.

16. Do not turn the battery upside down, electrolyte may pour down.

17. Flush spilled electrolyte with water and neutralize with lime.

18. Properly dispose of any old batteries.

7-50

7 - MAINTENANCE

1. Stop the engine and turn the power cut-off switch (1) to the Off position.

NOTICE: Wait 60 seconds after shutting off the ignition key before shutting off the power cut-off switch. This time is required for the Engine Control Module (ECM) to save the data.

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2. Clean the surfaces of the batteries (2).

3. Inspect the condition of poles and terminals (3). Clean the poles and terminals (3). Apply thin layer of grease on terminals.

4. When equipped with a maintenance-free battery, it is not necessary to check the electrolyte level for the whole service life of the battery.

5. Check the battery discharge condition and the lowest permissible voltage level (under which the battery could be damaged). Recharge as per battery manufacturers recommendations.

6. If the battery is not going to be used for longer time in the winter, remove and store the battery as explained below:

Battery storage 1. Remove the batteries from the machine. Store them on a wooden table in a dry, cool, well ventilated room, if possible at a temperature above 0 °C (32 °F) [optimum temperature 20 °C (68 °F)].

2. Perform the following operations: • Clean the battery.

• Check the acid concentration and the electrolyte level every two weeks.

• Fully recharge the battery every two weeks..

• Keep the outside of the batteries clean and dry.

7-51

7 - MAINTENANCE

Engine belts 1. With the unit stopped on a hard level surface, place the travel control in the park brake position.

2. Shut the engine off and remove the key from the unit.

3. Remove the engine guards (1).

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4. Check the tensioner pulley (2) for correct operation.

5. Check the belt visually.

6. When longitudinal cracks occur on the belt, belt edges are shattered, or extracted parts of material in the belt, the belt must be replaced.

7-52

7 - MAINTENANCE

Engine belt replacement 7. Loosen the bolts and move the compressor.

8. Take out the belt.

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9. Lift off the tensioner pulley (1) using a lever.

10. Remove the engine belt (2).

11. Install the new belt (2).

12. Reinstall the engine guards (3).

7-53

7 - MAINTENANCE

Drum drive reducer gearbox Refer to 7-30 for procedure.

Vibration system oil Refer to 7-35 for procedure.

7-54

7 - MAINTENANCE

Rubber isolation mounts 1. Check the condition of the drum rubber isolation mounts (1).

2. Replace any damaged rubber mounts (1).

3. Check the torque on all mounting bolts.

Number of drum rubber isolation mounts (1): 2 x 10

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Number of cab isolation rubber mounts (2): 4

7-55

7 - MAINTENANCE

Number of engine isolation rubber mounts (3): 4

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4

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Number of battery rubber isolation mounts (4): 8

Number of radiator rubber isolation mounts (5): 4

7-56

7 - MAINTENANCE

Water tank 1. Remove the cap (1) from the filler port of the tank.

2. Clean the strainer (2) of the filler ports.

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3. Open the drain plugs (3) and drain the tank.

7-57

7 - MAINTENANCE

Water / Oil / Intercooler Radiator NOTICE: Clean the Machine at a workplace equipped with cleaner collection system to prevent soil contamination and water resource contamination!

1. Remove the cover (1).

RAIL14COM0225AC

1

RAIL14COM0216AA

2

RAIL14COM0252AA

3

RAIL14COM0225AC

4

2. Remove the bolts (2) and remove the cover (3).

3.

CAUTION Flying debris!

Compressed air can propel dirt, rust, etc. into the air. Wear eye and face protection when using compressed air.

Failure to comply could result in minor or moderate injury.

C0049A

Clean with compressed air or pressurized water (steam). Clean in the direction from the fan side.

NOTICE: Do NOT clean the radiator with a high pressure washer or it could cause damage.

4. When radiator is contaminated with crude oil products, use a approved detergent to clean the radiator. Find out a cause of contamination and rectify.

NOTE: When using a detergent, follow the instructions for the detergent solution.

5. Reinstall the cover (3) with the bolts (2).

6. Reinstall the cover (1).

7-58

7 - MAINTENANCE

Engine 1. Check the engine mounting in the machine frame.

2. Check the rubber isolation mounts (1) for condition.

Replace if necessary.

3. Check screws and nuts for tightening.

4. Check the engine. Replace damaged parts.

5. Check the hoses, clamps and connections.

RAIL14COM0322AA

Engine and machine control modules/control units 1. Contact your CASE CONSTRUCTION dealer for carrying out diagnostics of the engine.

2. Contact your CASE CONSTRUCTION dealer for carrying out diagnostics of the machine.

7-59

1

7 - MAINTENANCE

Air-conditioning compressor drive belt (if equipped) Inspection of the air-conditioning belt tension 1. Press with your thumb at the spot where the belt length between pulleys is the longest; apply 110 N (25 lb).

2. The maximum play should not exceed 10 mm (0.39 in).

RAIL14COM0230AA

1

RAIL14COM0322AA

2

RAIL14COM0322AA

3

Inspection of the air-conditioning belt wear 3. Check the belt (1) visually.

4. If longitudinal cracks occur on the belt, or belt edges are shattered, or parts of material are extracted, then you must replace the belt.

Tensioning of the air-conditioning belt 5. Loosen screws and move the compressor.

7-60

7 - MAINTENANCE

Air-conditioning belt replacement: 6. Loosen the bolts and move the compressor.

7. Remove the damaged belt (1).

8. Install the new belt.

RAIL14COM0322AA

4

RAIL14COM0322AA

1

9. Tension the belt as shown in 1 and tighten the bolts on the compressor.

Air-conditioning compressor mounting (if equipped) 1. Check the air conditioner compressor bracket for cracks. Replace bracket if necessary.

7-61

7 - MAINTENANCE

Every 2000 hours or 2 years

Hydraulic oil and filter Draining CAUTION Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in minor or moderate injury.

C0107B

Hydraulic systems capacity: 60 L (15.9 US gal) 1. Remove the drain plug (1) and drain the oil into a suitable container.

NOTE: Approximate volume of drained fluid: 60 L (15.9 US gal).

NOTE: Hydraulic oil must be changed after season/operating condition changes or if the machine was not used for longer period of time.

NOTICE: Drain the oil when it is still warm, the oil will flow easily.

RAIL14COM0251AA

7-62

1

7 - MAINTENANCE

Filling 2. Check the drain plug gasket for condition, replace if necessary. Reinstall the drain plug.

3. Remove the cap (2) on the filler neck and fill until the sight gauge (3) shows the oil at the upper part of the sight glass.

RAIL16COM0111AA

Hydraulic oil specifications: NOTICE: Oil quality and cleanliness are of utmost importance for the reliability and life of the hydraulic system. Deviation from the prescribed oil specification may lead to severe damage and void warranty.

Use CASE AKCELA NEXPLORE™ FLUID, MAT 3525 or an oil meeting the following specification: • API GL-4 • ISO VG-32/46 • SAE 10W30 • DIN 51524 PART 3 HV46 • ISO VG-46 or use , TUTELA HYDROSYSTEM AW 46 , MAT 3508 or an oil meeting the following specification: • DIN 51524 PART 3 HV46 • ISO VG-46 The hydraulic system is factory‐filled with, CASE AKCELA NEXPLORE™ FLUID, MAT 3525 hydraulic oil.

This is an oil with a high viscosity index, which means that the oil remains fluid at low temperatures.

Only for machine that operate in hot environments, CASE AKCELA AW HYDRAULIC FLUID 68 HV ( MAT 3508) hydraulic oil or an oil meeting the following specification is recommended: • DIN 51524 PART 3 HV68 • ISO VG-68 NOTICE: Consult your dealer for the correct oil specification to be used.

7-63

2

7 - MAINTENANCE

Replacing the filter cartridge Replace the filter whenever the hydraulic fluid is replaced or when the hydraulic filter warning indicator (1) goes on in the display.

RAIL14COM0292AA

3

RAIL14COM0248AA

4

SS12C389

5

RAIL14COM0292AA

6

1. Remove the filter.

2. Clean the filter mounting surface with a lint free cloth.

3. Apply a thin layer of clean oil on the seal (3) of the new filter cartridge (4).

4. Manually tighten the filter cartridge (4) until the seal (3) touches the support. Tighten the filter by hand another 1/2 to 3/4 turn.

5. Make sure that the hydraulic filter clogged indicator (1) is not illuminated in the display.

7-64

7 - MAINTENANCE

Suction filter and strainer replacement 1. Drain the hydraulic tank.

2. Unbolt and remove the tank cover (1).

3. Remove and replace the suction filter (2) with a new filter.

4. Remove and replace the strainer (3) with a new strainer.

5. Remove and replace the filler neck breather (4) with a new filler neck breather.

6. Inspect the interior of the hydraulic tank. If dirt is present, thoroughly clean and flush the tank with clean new oil.

7. Verify that the O-rings (5) and seal (6) are in good condition and replace when necessary.

8. Reinstall the tank cover and tighten.

9. Fill hydraulic oil with clean new oil.

7-65

RAIL16COM0014AA

7

7 - MAINTENANCE

Engine coolant Capacity: 23 L (6.1 US gal) NOTE: Refer to page 7-9 for coolant type and change requirements if required.

WARNING Hot liquid under pressure!

Scalding can result from fast removal of the radiator cap. Check and service the engine cooling system according to the maintenance instructions in this manual.

Failure to comply could result in death or serious injury.

W0163A

CAUTION Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in minor or moderate injury.

SS12C364

1

RAIL14COM0220AA

2

RAIL14COM0228AA

3

C0107B

1. Stop the engine. Wait till the coolant temperature drops down to below 50 °C (122 °F).

2. Remove the cap (1) on the expansion tank.

3. Remove the coolant drain plug (2). Use a suitable container and collect the drained coolant.

7-66

7 - MAINTENANCE

4. Check the hoses for damage and missing clamps. Repair/replace as necessary.

5. Make sure that the radiator is not damaged, leaking and grills are dirty. Clean/repair as necessary.

SS12C397

4

SS12C456

5

RAIL14COM0297AA

6

RAIL14COM0219AA

7

Filling the coolant 6.

WARNING Chemical hazard!

When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions. Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers.

Obey all local and environmental regulations when disposing of chemicals.

Failure to comply could result in death or serious injury.

W0371A

Install the drain plug, fill the cooling system with new coolant.

7. Refill the coolant to max level. When filled wait for 2-3 minutes until air escapes and the coolant flow through out the circuit.

NOTICE: Max filling rate should be 10 L/min (2.6 US gpm).

8. Reinstall the cap (1).

9. Start the engine and let it run for 5 minutes or until the coolant temperature reaches 82 °C (180 °F).

10. Check for any leaks. Repair as necessary.

11. Stop the engine.

12. Check the coolant level on the indicator (2).

13. Make sure that the coolant level is between the lower (3) and the upper (4) portion of the indicator.

14. Top up the coolant as necessary.

7-67

7 - MAINTENANCE

Coolant specification and capacity Use CNH XHD HEAVY DUTY COOLANT / ANTI-FREEZE or a coolant meeting the following specification: • ASTM D6210 Type 1-FF NOTE: CASE AKCELA PREMIUM ANTI-FREEZE can also be used.

The coolant is a water and antifreeze mixture containing: • 50% water • 50% antifreeze The quality of the water should not exceed following limits: • Total hardness: 0.03% • Chlorides: 0.01% • Sulfates: 0.01%

7-68

7 - MAINTENANCE

As required

Bleeding the fuel system Bleed the fuel system when: Fuel filters are replaced.

Fuel pump is replaced.

After fuel system repair.

When the machine is stored for long term.

When having run out of fuel.

1. Use a suitable container to drain the fuel.

2. Set the ignition key switch to position I. 3. Loosen the bleed screws (1) on the fuel filter.

4. Bleed the system until bubble free fuel flows out of the bleed screws and tighten the screw.

RAIL14COM0327AA

1

RAIL14COM0225AC

1

Water / Oil / Intercooler Radiator Clean the Machine at a workplace equipped with cleaner collection system to prevent soil contamination and water resource contamination.

1. Due to various working conditions no regular cleaning interval can be set.

2. In case of work in a very dusty environment, perform daily cleaning. The radiator getting dirty will cause a reduced cooling performance and increased temperatures of engine coolant and hydraulic oil.

3. Remove the cover (1).

4. Clean the radiator with compressed air or pressure water (steam). Be careful not to damage the fins on the radiator with a high pressure washer. Clean in the direction from the fan side.

NOTE: Follow instructions on detergent packaging.

7-69

7 - MAINTENANCE

Scrapers Hinged scrapers 1. The machine is equipped with four hinged scrapers.

2. In position (1), the scraper is set in the transport position.

3. In position (2), the scraper is set in the service position.

4. In the service position, the scraper blade (3) is pushed by means of the gas struts (4) against the drum body.

RAIL14COM0324AA

1

RAIL14COM0256AA

2

Replacement of the blade: NOTICE: Only the correct function of the gas struts and the timely replacement of the worn out scraper blade will ensure perfect cleaning of the drum.

To replace the blade proceed as follows: 1. Set the scraper to position (1).

2. Remove the screws (5).

3. Remove the blade (3) from the strip (6).

RAIL14COM0257AA

7-70

3

7 - MAINTENANCE

Machine cleaning When the work is completed, clean the Machine to get rid of major impurities.

Carry out overall cleaning on regular basis, at least once per week. Total cleaning must be done daily if working on cohesive soils, cement or lime stabilization.

To clean the machine proceed as follows: 1. Stop the engine and remove the ignition key switch.

2. Turn the power cut-off switch to the Off position.

NOTICE: Wait 60 seconds after shutting off the ignition key before shutting off the power cut-off switch. This time is required for the Engine Control Module (ECM) to save the data.

3. NEVER use aggressive or easily ignitable cleaners 4. Before pressure cleaning with water or steam, plug all the ports with protective caps. Once cleaning is completed remove the protective caps.

5. Do NOT expose electric parts or insulation material to direct water or steam streams.

6. Clean the Machine at a workplace equipped with cleaner collection system so to avoid soil or water recourse contaminations!

7-71

7 - MAINTENANCE

Loose hardware Check all hardware for loosening. proper torques.

Refer to 7-2 for

7-72

7 - MAINTENANCE

Drain the water tank Before winter season it will be necessary to drain water from the sprinkling circuit to avoid any damage to the components due to freezing.

1. Remove sprinkling water tank drain plug (1) and drain the water.

2. Switch on the sprinkling pump till the remaining water in the system drains out.

RAIL14COM0244AA

1

RAIL14COM0224AA

2

RAIL14COM0229AA

3

3. Remove and store the sprinkling filter housing (2), screen (3) and O-rings (4).

7-73

7 - MAINTENANCE

4. Leave the valves (5) and (6) open.

RAIL14COM0224AA

4

RAIL14COM0253AA

5

RAIL14COM0255AA

6

RAIL14COM0319AA

7

5. Remove at least one sprinkler nozzle from each tube (7) on the front and rear side of the machine. Store the sprinklers safely.

6. Remove and store the edge cutter sprinkler (8) (if equipped).

7. To reinstall the removed parts, clean the parts thoroughly and proceed installation in reverse order.

7-74

7 - MAINTENANCE

Fuse and relay locations

Fuse panels Main fuse panel The main fuse panel is located on the rear cover in the operator’s cab. To access the fuse panel, remove the fuse cover (1) by removing the four retaining screws.

F1

15 A

F2

10 A

F3

7.5 A

F4

7.5 A

F5

7.5 A

F6

35 A

F7 F8

7.5 A 7.5 A

F11

5A

F12 F13

5A 10 A

F14

5A

F15

5A

F16

1A

F17 F18 F21

7.5 A 3A 10 A

F22

10 A

F23 F24 F25 F26 F27

10 A 10 A 20 A 5A 5A

Mounting socket Front parking lights, front headlamps, rear lights Rear headlamps Turn indicators, beacon, horn, cab lighting, coil of engine time relay (A10) Switch box, lighting relay coils Power supply of computer Rexroth RC20-10/30 Seat control Working lights, drum lighting Drum sensors (speed, frequency), el. magnets of vibration, water level sensor, infra thermometer, emulsion sprinkling relay Emulsion sprinkling Water sprinkling Brake lights, reverse horn, alternator excitation Total STOP, service mode Memory of computer Rexroth RC20-10/30 Lever Gessmann, display Diagnostic socket of engine Auto-radio Heating control, rear window heating control, air-conditioning relay Wipers, screen washers Heating fans Rear window heating Front working lights Rear working lights

NOTICE: Always replace the fuses with the ones of identical value.

7-75

RAIL16COM0113AA

1

RAIL16COM0009AA

2

7 - MAINTENANCE

Engine compartment fuse panel The engine compartment fuse box is located in the righthand engine service door.

F31 F32 F33 F34 F36 F37

80 A 15 A 10 A 15 A 125 A 30 A

Main fuse Air conditioning Fuel pump Auto-radio Pre-heating Engine electronics

NOTICE: Always replace the fuses with the ones of identical value.

RAIL16COM0137AA

3

RAIL16COM0114AA

4

RAIL16COM0115AA

5

Relays The relays are located behind the rear cover in the operator’s cab. To access the relay panel, remove the four retaining screws (1), then lower the cover (2).

7-76

7 - MAINTENANCE

Storage

Short term storage Store the machine as follows: • Wash and clean the machine.

• Run the engine until the engine warms up to its operating temperature before storing the machine.

• Park the machine on a firm, level surface at a secure place (with no risk of natural disaster - floods, landslides, fire, etc. to the machine).

• Repair any damaged paint spots.

• Grease all grease points, control cables, joints, etc.

• Drain the water tank (refer to 7-73 for procedure).

• Check for the required antifreeze properties of the coolant.

• Shut the power disconnect switch off.

• Disconnect the battery ground cables. If stored more than thirty days, charge the batteries on a thirty day cycle.

• Apply CASE AKCELA 251H EP MULTI-PURPOSE GREASE over the chrome finished surfaces and piston rods.

• Protect the machine against corrosion by spraying a preservation agent (applied spraying), particularly in places which are prone corrosion.

If the machine is preserved as explained above, no action is required when putting the machine back in service.

NOTICE: Do not start the engine during the storage period.

7-77

7 - MAINTENANCE

Storage longer than 2 months For long term storage (more than 2 months), follow all procedures mentioned in short-term storage (refer to 7-77) and follow the additional steps provided below: • Support the machine structurally to avoid damage to the rubber isolation mounts.

• Apply a special preservation agent to protect rubber parts.

• Cover the engine suction and discharge ports with double polyethylene foil and secure this foil thoroughly with adhesive tape.

• Protect the headlights, external rear view mirrors and other elements with external wiring by spraying a special agent and wrapping in polyethylene foil.

• Preserve the engine as described in the engine manufacturer’s instruction manual – visibly mark that the engine has been preserved.

NOTICE: Inspect the condition of preservation after 6 months and renew the preservation conditions as necessary.

7-78

7 - MAINTENANCE

Removing from storage To return the unit to service, perform the following: • Wash and clean the machine.

• Recharge the batteries and then reconnect the battery ground cables.

• Remove all machine storage supports.

• Remove the foil and adhesive tape from the engine suction and discharge ports.

• Drain any water from the fuel filter and tank.

• Check engine oil and coolant levels.

• Turn the power disconnect switch to On. • Start the engine and allow it to warm to operating temperatures.

• Shut the engine off and check for leaks. Repair as necessary.

7-79

7 - MAINTENANCE

7-80

8 - SPECIFICATIONS

8 - SPECIFICATIONS###_9_### General specifications Weight Operating weight of CECE with cab, ROPS Operating load of CECE with cab, ROPS on front axis Operating load of CECE with cab, ROPS on rear axis Weight of half fluid capacities Operating weight of ISO 6016 with cab, ROPS Max. weight – cab + ROPS (6016) + accessories + weighing Maximum permitted weight according to ROPS Static linear load of front drum Static linear load of rear drum Cab weight Weight of Ammann edge cutter Weight of two-sided edge cutter Weight of Ammann spreader Driving characteristics Maximum transport speed Climbing ability without vibration Climbing ability with vibration Lateral stability during driving with vibration Turning radius inner (edge) Turning radius outer (contour) Type of drive Number of driving axles Oscillation angle Angle of steering

9470 kg (20878 lb) 4720 kg (10406 lb) 4750 kg (10472 lb) 510 kg (1120 lb) 9560 kg (21076 lb) 10910 kg (24052 lb) 13000 kg (28660 lb) 28.1 kg/cm – 157.4 lb/in 27.3 kg/cm – 152.9 lb/in 440 kg (970 lb) 150 kg (330 lb) 300 kg (660 lb) 630 kg (1390 lb)

10 km/h (6.5 mph) 30% 25% 15% 5470 mm (215.4 in) 7450 mm (293.3 in) Hydrostatic 2 ±6° ±31°

Steering Type of steering Steering control Linear hydraulic motors

Joint Hydraulic 1 + 1 (Crab) Engine Deutz TCD3.6 L4 74.4 kW (100 Hp) 4 3621 cm³ (221 in³) 2200 RPM 410 N·m at 1600 RPM 9.8 L/hour (2.6 US gal/hour) EU Stage IIIB, U.S. EPA Tier 3 Liquid

Manufacturer Type Power according to ISO 14396 Number of cylinders Cylinder capacity Nominal speed Maximum torque Average fuel consumption Engines complies with emission regulations Cooling system of engine Brakes

Hydrostatic Mechanical multiple-disc Mechanical multiple-disc

Operating Parking Emergency

8-1

8 - SPECIFICATIONS

Vibration 42 Hz (2520 Vib/Min) 54 Hz (3240 Vib/Min) 0.7 mm (0.028 in) 0.34 mm (0.013 in) 84 kN (18884 lb) 68 kN (15287 lb) Hydrostatic

Frequency I Frequency II Amplitude I Amplitude II Centrifugal force I Centrifugal force II Type of drive Watering Type of watering Number of pumps Number of filtrations

Pressure 2 3 Wiring

Voltage Battery capacity

24 V 2x 55 A·h

Noise and vibration emissions Declared value of sound pressure A at operator's place (cab) Guaranteed sound power level A Highest weighted effective value of acceleration of vibrations transmitted to the whole body (cab) Total value of acceleration of vibrations transmitted to hands (cab)

8-2

82 dB 107 dB <0.5 m/s² (<1.6 ft/s²) <2.5 m/s² (<8.2 ft/s²)

8 - SPECIFICATIONS

Machine dimensions

RAIL14COM0307FC

1

A 3500 mm (137.8 in)

D 1220 mm (48 in)

H 3000 mm (118.1 in)

G1 780 mm (30.7 in)

G 300 mm (11.8 in)

L 4720 mm (185.8 in)

T 19 mm (0.7 in)

W 1680 mm (66.1 in)

W1 1800 mm (70.9 in)

C 170 mm (6.7 in)

8-3

8 - SPECIFICATIONS

RAIL14COM0309HC

8-4

2

9 - ACCESSORIES

9 - ACCESSORIES###_10_### Edge cutter Edge cutter and compactor are options supplied upon request. They are not included as standard accessories of the machine.

The edge cutters serial number can be found on the product identification plate (1).

RAIL14COM0319AA

1

RAIL14COM0275AA

2

Edge cutter plate 1. Name in English 2. Type 3. Serial number 4. Maximum weight 5. Year of manufacture

9-1

9 - ACCESSORIES

How to activate the edge cutter 1. Use the switch (1) to select the edge cutter (left/right).

2. Use the switch (2) to turn on the sprinkling pump.

3. The buttons (3) and (4) serve for setting the edge cutter (final compaction device) to the required position.

3. Upward (setting to the transport position).

4. Downward (setting to the working position).

4. The required position is being set while the button is pressed. After reaching the limit position in either direction, the cutter will automatically stop.

5. The cutting disc (A) can be replaced for the compacting disc (B).

RAIL16COM0011AA

3

RAIL14COM0209AA

4

6. To replace, remove the final compaction disc attachment. The not used cutting disc is to be fixed in the holder.

9-2

9 - ACCESSORIES

Infrared thermometer The infra thermometer (2) is enabled by turning on the ignition key and it will display the temperature of the rolled bitumen surface using a sensor. The measured temperature is indicated on the display (1) in °C or °F as set.

The green field shows the optimum temperature range for vibration compaction.

Adjustment of limits To adjust the upper and lower limit of the admissible asphalt temperature, do as follows: 1. Hold the OK button for about 4 seconds (or until the audible signal).

RAIL14COM0281AA

1

RAIL14COM0211AA

2

2. When the blue text “Set lower limit” appears and the digital temperature data is flashing, you can increase/ decrease the set value using the up/down arrows.

3. After the lower limit has been set, use the OK button to switch over to the upper limit setting.

4. When the red text “Set higher limit” appears and the digital temperature data is flashing, you can increase/ decrease the set value using the up/down arrows.

5. By pressing the OK button momentarily, you can anytime switch over between the upper and lower limit adjustment.

6. By pressing and holding the OK button for about 4 seconds (audible signal), you save the set values in the memory.

9-3

9 - ACCESSORIES

9-4

Index ###_Index_###

Air-conditioning compressor drive belt (if equipped) Air-conditioning compressor mounting (if equipped) Air-conditioning refrigerant level (if equipped) . .

Air filter dust valve . . . . . . . . . . . . . .

Air filter sensor . . . . . . . . . . . . . . . .

Air intake and cooling hoses . . . . . . . . . .

Assisted starting (jump-starting) . . . . . . . .

. . . . . . .

. . . . . . .

A . . . . . . . . . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . .

7-28, 7-60 . . 7-61 . . 7-42 . . 7-22 . . 7-40 . . 7-39 . . 7-15

B Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50 Before starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Bleeding the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-69 Cab access/exit . . . . . . . . . . . . . . . .

Cab ventilation air filters (if equipped) . . . . . . .

Changing to Organic Acid Technology (OAT) coolant CNH Industrial America LLC technical manuals . . .

Controls and alarms. . . . . . . . . . . . . . .

Cooling fan . . . . . . . . . . . . . . . . . .

. . . . . .

C . . . . . . . . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

Display screens . . . . .

Display unit . . . . . . .

Drain the water tank. . . .

Drum drive reducer gearbox

. . . . . .

. . . . . .

. . . . . .

. 3-1 . 7-42 . 7-9 . 1-2 . 7-26 . 7-22

. . . .

. . . .

. . . .

D . . . . . . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . . . 3-14 . . . . . 3-12 . . . . . 7-73 7-28, 7-30, 7-54

Ecology and the environment. . . . . . . . . .

Edge cutter . . . . . . . . . . . . . . . . .

Electro-Magnetic Compatibility (EMC) . . . . . .

Engine . . . . . . . . . . . . . . . . . . .

Engine accessory drive belt . . . . . . . . . .

Engine air filter . . . . . . . . . . . . . . . .

Engine and machine control modules/control units Engine belts . . . . . . . . . . . . . . . . .

Engine coolant . . . . . . . . . . . . . . . .

Engine coolant concentration level . . . . . . .

Engine coolant level. . . . . . . . . . . . . .

Engine cooling system . . . . . . . . . . . .

Engine fuel filter and pre-filter . . . . . . . . .

Engine fuel system pre-filter . . . . . . . . . .

Engine oil and filter . . . . . . . . . . . . . .

Engine oil level . . . . . . . . . . . . . . . .

Engines leaks . . . . . . . . . . . . . . . .

Exhaust system leaks . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . .

E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . .

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2-8 9-1 1-5 7-59 7-36 7-46 7-59 7-52 7-66 7-41 7-21 7-49 7-43 7-29 7-37 7-20 7-22 7-29

F Fluids, lubricants and capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Fuel tank level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23 Fuse panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75 G General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 General specification - Biodiesel fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 General specification - Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hand signals . . . . . . . . . . .

Heating and air conditioning controls Hydraulic oil and filter . . . . . . .

Hydraulic oil level . . . . . . . . .

Hydraulic system care . . . . . . .

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Infrared thermometer . . .

Intended use . . . . . . .

Interior component locations

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. 2-9 . 3-29 . 7-62 . 7-24 . 7-6

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Left-hand armrest controls . . .

Loose hardware . . . . . . .

Lubrication and service schedule Lubrication points . . . . . . .

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. 3-5 . 7-72 . 7-17 . 7-33

Machine cleaning . . . . . . . . . . . . . .

Machine components . . . . . . . . . . . .

Machine dimensions . . . . . . . . . . . .

Machine orientation . . . . . . . . . . . . .

Machine transport (on a trailer) . . . . . . . .

Machine travel and reversing . . . . . . . . .

Machine travel and reversing including vibration Maintenance chart . . . . . . . . . . . . .

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. 7-71 . 1-10 . 8-3 . 1-9 . 5-1 . 4-9 . 6-2 . 7-18

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N Note to the owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

O Operating conditions . . . . . . . . . . . . . . . . .

Operating with vibration on compacted and hard materials .

Operator's manual storage on the machine. . . . . . . .

Operator seat adjustments . . . . . . . . . . . . . . .

Overhead panel . . . . . . . . . . . . . . . . . . .

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P Parking the machine and stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power cut-off switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-11 7-5 1-6

R Radiator cooler fins . . . . . . . . . . . . . . . . . .

Rear panel . . . . . . . . . . . . . . . . . . . . . .

Recommended engine oil for operating temperature ranges Removing from storage . . . . . . . . . . . . . . . .

Right-hand armrest controls . . . . . . . . . . . . . .

Rubber isolation mounts . . . . . . . . . . . . . . . .

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Safety rules . . . . . . . . . . . .

Safety rules and signal word definitions Safety signs . . . . . . . . . . . .

Scrapers . . . . . . . . . . . . .

Short term storage . . . . . . . . .

Sprinkling . . . . . . . . . . . . .

Starting the engine . . . . . . . . .

Steering column controls . . . . . .

Stopping the machine . . . . . . . .

Storage longer than 2 months . . . .

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2-2 2-1 2-12 7-70 7-77 6-4 4-4 3-4 4-7 7-78

T Tightening torques . . .

Towing the machine . . .

Transport mode . . . .

Traveling on public roads

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V Vibration system oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water / Oil / Intercooler Radiator Water filter . . . . . . . . . .

Water tank . . . . . . . . . .

Window washer tank . . . . .

Wiring . . . . . . . . . . . .

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. 7-2 . 5-4 . 3-28 . 5-1

7-35, 7-54

. 7-58, 7-69 . . . . 7-31 . 7-25, 7-57 . . . . 7-5 . . . . 7-41

Dealer’s stamp

CNH Industrial America LLC reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold.

Specifications, descriptions, and illustrative material herein are as accurate as known at time of publication, but are subject to change without notice.

Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your Case dealer.

© 2016 CNH Industrial America LLC. All Rights Reserved.

Case is a trademark registered in the United States and many other countries, owned or licensed to CNH Industrial N.V., its subsidiaries or affiliates.

Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.