Case DV209C DV210C Tier 4A Vibratory Roller Operator's Manual 47772902 - PDF DOWNLOAD

DV209C DV210C Tier 4A Vibratory Roller

OPERATOR’S MANUAL

Part number 47772902 1st edition English September 2014

Contents 1 GENERAL INFORMATION Note to the owner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Intended use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Electro-Magnetic Compatibility (EMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Operator's Manual storage on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Machine orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Machine components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Exhaust Gas Recirculation (EGR) system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

2 SAFETY INFORMATION Safety rules and signal word definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Safety rules - California Proposition 65 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Safety rules - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Safety rules - Basic operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 General maintenance safety rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Safety rules - Fire or explosion prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Safety rules - Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Safety rules - Operator presence system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Safety rules - Seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Safety rules - Roll Over Protective Structure (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Safety rules - Air-conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Personal Protective Equipment (PPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Do Not Operate hang tag. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Safety rules - Hazardous chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Safety rules - Utility precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Safety rules - Electrical storm safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Safety rules - Mounting and dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Ecology and the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 Hand signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 Safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

3 CONTROLS AND INSTRUMENTS Access to operator's platform Access to operator's platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Operator's seat Operator seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Forward controls Steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Left-hand side controls Left-hand side controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Right-hand side controls Right-hand side controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Rearward controls Rearward controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Overhead controls Overhead controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Exterior controls Exterior controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Display Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display screens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ignition lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transport mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-15 3-17 3-27 3-28

CLIMATE CONTROLS Heating and air-conditioning controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

CAB CONTROLS AND ADJUSTMENTS Cab - Control identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

4 OPERATING INSTRUCTIONS Commissioning the unit De-conservation and inspection of brand new machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Operating the machine during running-in period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Starting the unit Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Assisted starting (Jump-starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Stopping the unit Stopping the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Moving the unit Machine travel and reversing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Parking the unit Machine parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

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

Shipping transport Machine transport (on a trailer). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

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

6 WORKING OPERATIONS General information Operating the machine at low temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating the machine at high temperatures and humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating the machine at high altitudes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating the machine in extremely dusty environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1 6-2 6-3 6-4

Compaction Machine travel and reversing including vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Sprinkling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Operating with vibration on compacted and hard materials . . . . . . . . . . . . . . . . . . . . . . . . 6-8

7 MAINTENANCE General information Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Biodiesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fluids and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil viscosity — Recommended operating temperature range . . . . . . . . . . . . . . . . .

Lubrication and service schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1 7-4 7-7 7-8 7-9

Maintenance planning Maintenance chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

Every 20 hours of operation or daily Engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine - Check for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Air filter vacuum valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

7-13 7-14 7-15 7-16 7-17 7-18 7-19 7-20

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

Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air-conditioning compressor drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

7-21 7-23 7-24 7-25

Every 250 hours of operation or every 3 months Water filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26 Grease points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

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

Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intake manifold - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air-conditioning refrigerant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air-conditioning system filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

7-31 7-32 7-35 7-36 7-37 7-38 7-39 7-40 7-41 7-42 7-46

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

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

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

Gearbox oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vibrations system oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Suspension and silencing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

Air-conditioning compressor drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air-conditioning compressor mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic oil and filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-49 7-50 7-52 7-53 7-54 7-55 7-57 7-58 7-59 7-60 7-61 7-63 7-64

Every 2000 hours of operation or every 2 years Engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68

As required Fuel system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Cab ventilation air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drain water from the sprinkling circuit before winter season . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

7-71 7-72 7-73 7-74 7-76 7-77

Storage Short term storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-78 Machine preservation and storage for longer than 2 month. . . . . . . . . . . . . . . . . . . . . . . 7-79

8 SPECIFICATIONS General specification – DV209C and DV209C HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 General specification – DV210C and DV210C HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

9 ACCESSORIES Edge cutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Infrared thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Telematics - Overview with Case SiteWatch™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

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.

Contact your dealer for any further information or assistance about your equipment. Your dealer has CASE CONSTRUCTION approved service parts. Your dealer has technicians with special training that know the best methods of repair and maintenance for your equipment.

Your CASE CONSTRUCTION Dealer is available for any further information. CASE CONSTRUCTION Customer Service is also available. Call 1-888-365-NHCE (1-888-365-6423) or email customerservice.na@cnh.com.

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1 - GENERAL INFORMATION

Intended use DV209 – compactors have been designed to perform medium and large-sized compaction works in transport construction (roads and motorways, airfields) and building construction (industrial zones, etc.).

Rollers are suitable for compacting the asphalt mixtures up to a layer thickness (after compaction) of 150 mm (5.91 in), hydraulically consolidated mixtures up to a layer thickness of 220 mm (8.66 in), mixed soils up to a layer thickness of 320 mm (12.60 in) and sand and gravel materials up to a layer thickness of 420 mm (16.54 in).

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

RAIL14COM0280AA

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.

D0118A

CAUTION 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.

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.

C0160A

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

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.

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

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

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 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.

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 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.

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1 - GENERAL INFORMATION

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.

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

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.

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

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

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1 - GENERAL INFORMATION

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.

1-4

1 - GENERAL INFORMATION

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 provides the following information: 1. Type / Model 2. Product Identification Number (PIN)

RAIL14COM0213AA

1

RAIL14COM0348BA

2

RAIL14COM0259AA

3

Machines PIN can also be located on the front frame as indicated (1).

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1 - GENERAL INFORMATION

Engine Engine identification plate (1) is located below the Machine identification plate

RAIL14COM0213AA

4

RAIL14COM0260AA

5

Roll Over Protective Structure (ROPS) ROPS identification plate (1) is located on the protective structure inside the cab

1-6

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

1-7

1

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.

1-8

1

Left side Right side

1 - GENERAL INFORMATION

Machine components

RAIL14COM0271HC

1-9

1

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.

1-10

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

Exhaust Gas Recirculation (EGR) system What is Exhaust Gas Recirculation (EGR)?

Your CASE CONSTRUCTION machine is equipped with additional components to comply with national and local exhaust emissions requirements. EGR works by recirculating a portion of the engine exhaust gasses back into the engine combustion chamber to lower combustion temperatures.

The main components of the EGR system include: • EGR valve • Diesel Particulate Filter (DPF) • Diesel Oxidation Catalyst (DOC) • Exhaust gas temperature sensors • Differential pressure sensor • Throttle valve actuator

What is a Diesel Particulate Filter (DPF)?

A Diesel Particulate Filter (DPF) is a filter mounted in the exhaust stream. During normal operating conditions, the exhaust gasses pass through the porous walls of the DPF and trap Particulate Matter (PM) generated by the combustion process of the engine. When channels inside the DPF fill up with PM, the system must be cleaned. The cleaning process is called regeneration.

How does the regeneration process work?

When the DPF becomes restricted, the system will need to be cleaned or regenerated by raising exhaust temperatures to burn off the trapped Particulate Matter (PM). This process is usually done automatically, but may require a manual regeneration sequence to be activated depending on operating conditions. Burned PM will leave behind traces of ash within the DPF. The ash must be cleaned out by a CASE CONSTRUCTION dealer outfitted with machines specifically designed to clean DPF systems. See Page 7-11 for service intervals.

Automatic regeneration When the DPF enters automatic regeneration mode, the display will indicate “DPF ON”. Several conditions need to be followed to properly let the machine perform this function.

• During this mode do not idle or shut the machine down.

• Hot exhaust gasses will be generated. Use in a well ventilated area away from combustible materials.

• Use the machine under normal work scenarios until the automatic regeneration process has completed.

• If the machine will be idled during this time, shut the machine down and perform a manual regeneration upon resuming operations.

Manual regeneration When automatic regeneration of the DPF is inhibited or unsuccessful, or the machine had to be shut down during the automatic regeneration process, manual regeneration is used. During the manual regeneration mode, the display will indicate “DPF ON”. Several conditions need to be followed to properly let the machine perform this function.

• During this mode, the machine will be unusable • Move the machine to a safe place away from combustible materials.

• Hot exhaust gasses will be generated. Use in a well ventilated area away from combustible materials.

• Let the regeneration finish before shutting the machine off.

Finding a Diesel Particulate Filter (DPF) cleaning facility To find a CASE CONSTRUCTION dealer that is fully equipped to service your DPF system, please call the number below.

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1 - GENERAL INFORMATION

Case Customer Assistance: 1-866-542-2736 casecustomerassistance.na@cnh.com

US Environmental Protection Agency (EPA) and California Emissions Control Warranty Statement CASE CONSTRUCTION warrants to the ultimate purchaser and each subsequent purchaser that the engine is designed, built and equipped so as to conform with US Environmental Protection Agency regulations applicable at the time of manufacture and that it is free from defects in workmanship or material which would cause it not to meet these regulations for a period of: • 2 years or 1,500 hours of operation, whichever occurs first, for engines less than 19 kW (25 Hp).

• 5 years or 3,000 hours of operation, whichever occurs first, for engines greater than or equal to 19 kW (25 Hp).

NOTE: This warranty applies to all units operated in the United States or Canada.

Coverage The model year, class of diesel engine, and emission application determination for your engine are identified on the Emission Control Information Label. This label is affixed to one of the following areas of the engine: the top of engine's rocker arm cover, the right-hand side of the oil pan, and the right-hand side of the engine front gear cover.

The warranty period begins on the date the new equipment is sold to the first retail purchaser. The presence of the emission control label is the indication that the engine conforms to the applicable standards. Any emission control system parts which are proven defective during normal use will be repaired or replaced during the warranty period.

The engine owner has responsibility to perform all the required maintenance listed in the Owner's Manual. CASE CONSTRUCTION will not deny an emission warranty claim solely because no record of maintenance exists; however, a claim may be denied if failure to perform maintenance resulted in the failure of a warranted part.

It is recommended that replacement parts used for maintenance or repairs be CASE CONSTRUCTION Service Parts to maintain the quality originally designed into your emission certified engine. The use of non- CASE CONSTRUCTION parts does not invalidate the warranty on other components unless the use of such parts causes damage to warranted parts.

The manufacturer is liable for damages to other engine components caused by the failure of any warranted emission control system part. CASE CONSTRUCTION is not responsible for failures resulting from improper repair or the use of parts that are not genuine CASE CONSTRUCTION or CASE CONSTRUCTION approved parts.

Component coverage New engines certified for sale and registered will have the following items covered by the emission warranty, depending on the emission level of the engine, if the items were first installed on the new engine as original equipment: Fuel injection system

Exhaust after treatment Devices (if applicable)

• Fuel injection pump

• Catalytic converter (DOC)

• Fuel injectors

• Diesel particulate filter (DPF)

• Fuel injection lines

• Selective catalytic reduction (SCR)

Air induction system

• Diesel Exhaust Fluid (DEF) tank and dispensing systems

• Intake manifold • Turbocharger system (includes exhaust manifold) • Charge air cooler Positive crankcase ventilation system (if applicable) • PCV valve • Oil fill cap

Exhaust Gas Recirculation Systems (EGR) • EGR valve assembly • EGR cooler Cold Start Enrichment Systems Electronic Control Units, Sensors, Solenoids, and Wiring harnesses used in above systems

1-12

1 - GENERAL INFORMATION

Emissions warranty does not cover • Repairs arising from storage deterioration, failure to maintain the equipment, negligence, alteration, improper use of the equipment, collision or other accident, vandalism, or other casualty, or operation beyond rated capacity or specification.

• Repairs arising from abuse or neglect, including but not limited to: operation without adequate coolant or lubricants, adjustments to the fuel system outside equipment specifications, over-speeding, improper storage, starting, warmup, or shutdown practices, incorrect fuel or contaminated fuel, oil or other fluids.

• Normal maintenance services, such as engine tune-ups, engine fuel system cleaning, checks, adjustments, shimming, etc.

• Items replaced due to customer demand.

• Labor charges performed by anyone except a dealer authorized by contract to repair the equipment, unless they qualify under special provisions (i.e. outside labor).

• Any and all travel costs for items such as towing, service calls, or transporting a unit to and from the place where the warranty service is performed.

• Normal maintenance costs, including but not limited to: lubricants, coolants, fluids, fuel, filters, and associated labor.

Lubricants, filters, and coolants may qualify for warranty reimbursement if they require replacement as a DIRECT RESULT of a defect in material or workmanship.

• Claims involving the inspection or reconditioning of units after storage or prior use.

• Repairs arising from service performed by agents not approved by CASE CONSTRUCTION. • Repairs arising from any unauthorized modification to the product or the use of non- CASE CONSTRUCTION parts, implements or attachments.

• Removal, replacement, or installation of non- CASE CONSTRUCTION optional equipment, attachments or components.

• Premiums charged for overtime labor costs or out of shop expenses.

• Economic loss including lost profits, crop loss, equipment rental, or other expense.

• Unauthorized modification or updating machines without a warrantable failure.

• Any and all costs of dealer shop supplies incurred with repairs, including but not limited to: solvents, cleaners, anti-seize lubricants, loctite, sealant, adhesive, oil-dry, shop towels, etc.

• Failure of the machine, its implements or attachments caused by improper field application or loading.

• Any and all costs for coolant, fuel, or lube (oil) analysis including supplies and lab recommendations.

• Cost associated with cleaning of machine in preparation for servicing.

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1 - GENERAL INFORMATION

1-14

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.

2-1

2 - SAFETY INFORMATION

Safety rules - California Proposition 65 Warning

RCIL08CCH001EAA

1

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

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

2-2

2 - SAFETY INFORMATION

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.

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.

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

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

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

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

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

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

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.

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 operate the engine in enclosed spaces as harmful exhaust gases may build up.

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

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

• Make sure that all components are in good condition.

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

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.

• 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.

Wear protective equipment when appropriate.

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

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

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

2-3

2 - SAFETY INFORMATION

Before you leave the machine:

2. Disengage all drive systems.

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

3.

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

Some components may continue to run down after disengaging drive systems.

Make sure all drive systems are fully disengaged.

Failure to comply could result in death or serious injury.

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

4. Turn off the engine and remove the key.

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:

WARNING

W0113A

Shift the transmission into neutral.

4. Apply the parking brake.

1. Bring the engine to low idle speed.

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 NOTICE: The standard type of the machine is not intended for driving on public road. When on the road, the machine should be transported on a vehicle. In the unavoidable situation to drive the machine on public roads for shorter distances, follow the below safety precautions.

Comply with local laws and regulations.

the SMV on the equipment or machine is covered while being transported on a trailer.

Use appropriate lighting to meet local regulations.

Make sure that the SMV emblem is visible.

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

When you transport equipment or a machine on a transport trailer, make sure that it is properly secured. Be sure

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

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

Slow down and signal before turning.

2-4

2 - SAFETY INFORMATION

Pull over to allow faster traffic to pass.

Follow correct towing procedure for equipment with or without brakes.

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.

2-5

2 - SAFETY INFORMATION

Seat belts Seat belts must be worn at all times.

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

Seat belt inspection and maintenance: • Keep seat belts in good condition.

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

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

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

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

• Keep seat belts clean and dry.

• Clean belts only with soap solution and warm water.

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

• Replace all parts that have damage or wear.

To fasten the belt, pull the belt from the reel and push the metal end into the latch mechanism end until a “click” sound indicates it is properly engaged.

To release, press the red release button on the latch mechanism and remove the metal end from the latch mechanism.

SS12C077

1

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

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.

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 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.

• All damaged parts MUST BE REPLACED. DO NOT WELD, DRILL HOLES, ATTEMPT TO STRAIGHTEN, OR REPAIR THE PROTECTIVE STRUCTURE. MODIFICATION IN ANY WAY CAN REDUCE THE STRUCTURAL INTEGRITY OF THE STRUCTURE, WHICH COULD CAUSE DEATH OR SERIOUS INJURY IN THE EVENT OF FIRE, TIP 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.

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2 - SAFETY INFORMATION

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.

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.

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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.

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

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

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Safety rules - General

Understand that your safety and the safety of other workers or bystanders is measured by how you service and operate this machine. Know the positions and operation of all controls before you try to operate. CHECK ALL CONTROLS IN A SAFE AREA BEFORE STARTING YOUR WORK. READ THIS MANUAL COMPLETELY and make sure you understand the controls. All equipment has a limit. Make sure you understand the speed, brakes, steering, stability, and load characteristics of this machine before you start to operate.

Most accidents involving machine operation and maintenance can be avoided by following basic safety rules and precautions. Read and understand all the safety messages in this manual, the safety manual and the safety decals on the machine before you operate or service the machine. See your dealer if you have any questions.

The safety information given in this manual does not replace safety codes, insurance needs, or federal, state, and local laws. Make sure your machine has the correct equipment according to these rules or laws.

CASE CONSTRUCTION. is continuing to work for your safety by making loader backhoes with better protection and by providing rules for safe operation.

• Do not rush. Walk, do not run.

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

• Wear protective equipment when appropriate. Hard hats, protective glasses, protective shoes, gloves, reflector type vests, respirators, and ear protection are examples of equipment that may be required.

• Certain protective equipment should be replaced and renewed upon age and wear. Old hard hats may not be as per the original safety requirements. Faded and soiled reflector type vest are not as bright as the new ones. See the manufacture’s recommendation and replace accordingly.

• Wear the seat belt to maximize the protection capability of the cab or ROPS. Inspect the mounting bolts for the seat belt and the ROPS, if equipped, on a daily basis to ensure their integrity.

• Do not permit riders on the machine or attachments.

• Remove all loose objects stored in the machine. Remove all objects which do not belong in or on the machine and its equipment.

• Do not operate this machine or perform maintenance work if you have not had appropriate training, and read and fully understand the instructions and warnings in this manual.

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Safety rules - Basic operating

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

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

Make sure all drive systems are fully disengaged.

Failure to comply could result in death or serious injury.

W0113A

operate the machine with the shields removed. Always close access doors or panel before operating the machine.

• Always check the operating safety of the machine before starting.

• Always make sure the working area is clear of other persons, domestic animals, tools, etc. before you start operating the machine.

• Before starting the engine, be sure all operating controls are in the neutral or park lock position.

• Another worker or bystander 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.

• Start the engine only from the operator’s seat.

• Always sound horn before starting the machine.

• Do not allow other persons to ride on the machine or on an attachment/implement.

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

• Check brakes, steering, and other machine control devices in accordance with maintenance instructions, prior to starting operation. Observe all gauges or warning instruments for proper operation. Operate all controls to ensure proper operation. If any malfunctions are found, remove the key and attach a 'Do Not Operate' tag on the machine until the malfunction is corrected.

• If a failure that causes loss of control such as steering, service brakes, or engine occurs, stop the machine motion as quickly as possible. Make sure the machine is securely parked. Remove the key and attach a 'Do Not Operate' tag on the machine until the malfunction is corrected or the machine can be safely towed.

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

• Make sure all guards and shields are in good condition and properly installed before operating machine. Never

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

• Operate and drive the machine with care and at speed compatible with conditions. Use extra caution when operating over rough ground, on slopes, and when turning.

• If your machine has a cab, make sure that all windows are clean and that the windshield wipers work correctly.

• Dust, fog, smoke, etc., can decrease your vision and cause an accident. Stop the machine or decrease the speed until you can see.

• Understand the machine limitations and keep the machine under control.

• Before you operate at night, check that all lamps illuminate.

• Select a gear that will prevent excessive speed when going downhill. Do not coast downhill.

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

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• Before leaving the vehicle:

• Reduce engine speed to low idle.

• Park the vehicle on a hard, level surface.

• Disengage all drive systems.

• Put all controls in neutral or park lock position.

• Put the transmission in neutral.

• Engage the parking brake; use wheel chocks if required.

• Apply the parking brake.

• Shut down the engine and remove the key.

• In a rare circumstance when the engine must be running without an operator in the cab, take these precautions:

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General maintenance safety rules

coolant can spray out if a cap is removed while the system is hot. Allow the system to cool before removing cap. When removing a cap, turn it slowly to allow pressure to escape before completely removing the cap.

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

• Service machine on firm level surface.

• Do not attempt service unless trained. Refer to manuals and experienced service personnel for help.

• Wear gloves to protect hands when handling cables.

• Engine, transmission, exhaust components, and hydraulic lines may become hot during operation. Take care when servicing such components. Allow surfaces to cool before handling or disconnecting hot components. Wear protective equipment where appropriate.

• Disconnect the battery before working on the electrical system. Know the consequences of disconnecting any electronic or computer devices.

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

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

• When replacing hardened pins, use a brass drift or other suitable material between the hammer and pin.

• Wear protective glasses and other required safety equipment when servicing the machine.

• If the engine must be in operation to make certain adjustments, place the transmission in neutral, apply the parking brake, place the equipment in a safe position, securely block the wheels, and use extreme caution.

• 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 securely supported.

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

• Shut down the engine and remove the key before disconnecting or connecting electrical components.

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

• When welding, follow the instructions in this manual.

Always disconnect battery before welding on machine.

Always wash your hands after handling battery components.

• Keep the brakes and steering systems in good operating condition.

• Replace all missing, illegible, or damaged safety signs.

Keep all safety signs clean.

• Install guards and shields after servicing the machine.

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

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

• Scalding can result from incorrect removal of coolant caps. Cooling system operates under pressure. Hot

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Safety rules - Fire or explosion prevention

• Leaked or spilled fuel/oil on hot surfaces or electrical components can cause a fire.

of the machine may be necessary depending on the operating environment and conditions.

• Sparks from the electrical system or engine exhaust can cause an explosion and fire. Before you operate the machine in an area with flammable dust or vapors, use good ventilation to remove the flammable dust or vapors.

• If the machine has an oil, fuel, or hydraulic fluid leak, always repair the leak and clean the area before operating.

• Engine fuel can cause an explosion or fire. Do not fill the fuel tank with the engine running, if you are near an open fire, or if you are welding, smoking, etc.

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

• Always have a fire extinguisher near or on the machine.

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

• If a fire extinguisher has been used, always recharge or replace the fire extinguisher before operating the machine.

• Keep the cooling system clean and maintain the correct coolant level.

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

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

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

• If you weld, grind, or use a cutting torch on the machine: • Clean the area to be repaired.

• Disconnect or isolate the drive train controller.

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

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

• Keep the ground cable from the welder as near to the work area as possible.

• Sparks or flame can cause the hydrogen gas in a battery to explode. To prevent an explosion:

• At least once each day, remove debris accumulation around moving components such as bearings, pulleys, belts, gears, cleaning fan, etc. More frequent cleaning

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• Connect the negative (-) cable last.

• When connecting booster cables to start the engine, use the procedure shown in this manual.

• Do not short circuit the battery posts with metal items.

• Do not weld, grind, or smoke near the battery.

2 - SAFETY INFORMATION

Safety rules - Battery

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.

Failure to comply could result in death or serious injury.

W0111A

• Follow manufacturer's instructions when storing and handling batteries.

• Always wear eye protection when working with a battery.

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

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

• Ventilate when charging or using a battery in an enclosed area.

• When disconnecting the battery terminals, remove the negative (-) cable first; then remove the positive (+) cable. When connecting the battery terminals, connect the positive (+) cable first; then connect the negative (-) cable.

• Disconnect the battery (both terminals) before welding on any part of the machine. Failure to do so may cause damage to sensitive electrical components. For additional welding precautions, refer to this chapter.

• When using auxiliary batteries or connecting booster cables to start the engine, use the procedure shown in this manual. DO NOT short across terminals.

• When working around storage batteries, remember that all of the exposed metal parts are “live”. Never lay a metal object across the terminals because a spark, short circuit, explosion, or personal injury may result.

• Frozen electrolyte can cause the battery to explode. Do not charge a frozen battery or use a frozen battery to booster start the machine. Always keep the battery at full charge to prevent the electrolyte from freezing.

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

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

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Safety rules - Operator presence system 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

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.

If the operator presence system is not functional, contact your CASE CONSTRUCTION dealer to get the system repaired.

Never disconnect or bypass the operator presence system.

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Safety rules - Seat belt

WARNING Roll-over hazard!

Securely fasten the seat belt. Your machine is equipped with a Roll-Over Protective Structure (ROPS) cab, ROPS canopy, or ROPS frame for your protection. 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.

Failure to comply could result in death or serious injury.

W0143A

Seat belts must be worn at all times.

• Keep seat belts in good condition.

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

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

• Replace all parts that have damage or wear.

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

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

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

• Keep seat belts clean and dry.

• Clean belts only with soap solution and warm water.

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

Fasten/release 1. Pull the right-hand belt strap from the retractor.

2. Insert the metal end into the latch mechanism of the left-hand side of the seat.

RCPH10TLB155AAF

1

RCPH10TLB156AAF

2

3. To release, press the red button on the latch mechanism. The seat belt will automatically retract.

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Safety rules - Roll Over Protective Structure (ROPS)

WARNING Roll-over hazard!

After an accident, fire, tip over, or roll over, a qualified technician MUST replace the Roll-Over Protective Structure (ROPS) before returning the machine to the field or job site operation.

Failure to comply could result in death or serious injury.

W0134A

WARNING Misuse hazard!

Your machine is equipped with an operator protective structure. 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.

Failure to comply could result in death or serious injury.

W0001B

DANGER Crushing hazard!

DO NOT operate the machine with the Roll-Over Protective Structure (ROPS) removed. Remove the ROPS only for service or replacement.

Failure to comply will result in death or serious injury.

D0032A

Your machine is equipped with an operator Protective Structure, such as: Rollover Protective Structure (ROPS) or Falling Object Protective Structure (FOPS). A ROPS may be a cab frame or a two posted or four posted structure used for the protection of the operator to minimize the possibility of serious injury. The mounting structure and fasteners forming the mounting connection with the machine are part of the ROPS. The protective structure is a special safety component of your machine.

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

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 side operation: • The protective structure MUST be replaced.

• The mounting or suspension for the protective structure, operator's seat and suspension, seat belt and mounting components, and wiring within the protective structure MUST be carefully inspected for damage.

• All damaged parts MUST be replaced.

DO NOT WELD, DRILL HOLES, ATTEMPT TO STRAIGHTEN, OR REPAIR THE PROTECTIVE STRUCTURE. MODIFICATION IN ANY WAY CAN REDUCE THE STRUCTURAL INTEGRITY OF THE STRUCTURE WHICH COULD CAUSE DEATH OR SERIOUS INJURY IN THE EVENT OF FIRE, TIP OVER, ROLL OVER, COLLISION, OR ACCIDENT. Seat belts are part of the 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.

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A ROPS label (1) is fastened to the protective structure and shows the ROPS PIN, the gross weight, approval, regulation, and model numbers of the machine.

RAIL14COM0260AA

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Safety rules - 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.

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

• Only a trained service technician shall service, repair or recharge the air-conditioning system.

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Personal Protective Equipment (PPE) WARNING Personal Protective Equipment (PPE) required.

When assembling, operating, or servicing the machine, wear protective clothing and PPE necessary for the particular procedure. Some PPE that may be necessary includes protective shoes, eye and/or face protection, hard hat, heavy gloves, filter mask, and hearing protection.

Failure to comply could result in death or serious injury.

W0353A

Personal protective equipment (PPE) is any equipment intended to be put on and kept by the worker for protection against one or more risks at work, liable to threaten safety or health during work, as well as all the complements or accessories intended for this purpose.

Wear PPE such as hard hat, eye protection, heavy gloves, hearing protection, protective clothing, etc at all times working on the machines as instructed in this manual.

PPE must be used when, in spite of the risk being reduced to a minimum at source, there are however risks that cannot be eliminated and therefore it becomes necessary and obligatory when there are so-called “residual” risks.

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DCAPLT5NE020S2A

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Do Not Operate hang tag Before you start servicing the machine, attach a 'Do Not Operate' warning tag to the machine. Attach the tag in an area that is easily visible.

• English 84427341 • Spanish 84427340 • French 84427332

LEEN12T0563BA

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Safety rules - Hazardous chemicals

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

The fluids, lubricants, paints, adhesives, coolants, etc. required for the function of the 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 chemical substances within a product, safe handling procedures, first aid measures, and procedures to be taken in the event of a spill or accidental release. MSDS are available from your dealer.

• Before you service the machine, check the MSDS for each lubricant, fluid, etc. used in the machine. This information indicates the associated risks and will help you service the machine safely. Follow the information

in the MSDS, on manufacturer's containers, as well as the information in this manual when servicing the machine.

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

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

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Safety rules - Utility precautions

• During operation it is likely that you will be working around or near buried utility lines which may include, but are not limited to:

• Make sure 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.

• Electrical power line • Gas line • Water line • Communication line - telephone or cable television • Sewer line • 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.

• Retract raised or extended components, if necessary.

Remove or lower radio antennas or other accessories.

Should contact occur between the machine and an electric power source, the following precautions must be taken:

• In U.S.A. and Canada call one of many One Call System Director services. If you do not know the local number, call the national number (U.S.A. and Canada only): 1-888-258-0808. This number will direct you to the state or regional utility that assists with excavation activity.

• After locating any buried utility lines, carefully dig a hole by hand and/or automatic vacuum equipment to the utility line to verify the location and depth of the line.

• Where applicable, know the utility color code.

Electric Gas, oil, or petroleum Communication, telephone, television Water Sewer Proposed excavation Surveying Reclaimed water and slurry

Red Yellow Orange Blue Green/Brown White Pink Purple

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• Stop the machine movement immediately.

• Apply the parking brake, shut down 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 you do not make contact with the ground and machine at the same time.

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

2 - SAFETY INFORMATION

Safety rules - Electrical storm safety

• Do no 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 cab or operator's platform. Do not make contact with the ground or objects outside the machine.

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Safety rules - Mounting and dismounting

• Face the machine when mounting and dismounting.

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

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

• Do not use the steering wheel or other controls or accessories as hand holds when entering or exiting the cab or operator's platform.

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

• Do not jump off the machine.

• Never mount or dismount from a moving machine.

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Ecology and the environment Soil, air, and water are vital factors of agriculture and life in general. When legislation does not yet rule the treatment of some of the substances required by advanced technology, sound judgment should govern the use and disposal of products of a chemical and petrochemical nature.

NOTE: The following are recommendations that may be of assistance: • Become acquainted with and ensure that you understand the relative legislation applicable to your country.

• Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, antifreeze, cleaning agents, etc., with regard to their effect on man and nature and how to safely store, use, and dispose of these substances.

• Agricultural consultants will, in many cases, be able to help you as well.

Helpful hints • Avoid filling tanks using cans or inappropriate pressurized fuel delivery systems that may cause considerable spillage.

• In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of them 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 draining off used engine coolant mixtures, engine, gearbox and hydraulic oils, brake fluids, etc.

Do not mix drained brake fluids or fuels with lubricants. Store them safely until they can be disposed of in a proper way to comply with 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 will have to recharge the system properly.

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

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

• Protect hoses during welding as penetrating weld splatter may burn a hole or weaken them, allowing the loss of oils, coolant, etc.

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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

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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

LEEN11T0010AA

6

LEEN12T0534AA

7

Go this far

All stop and hold

Stop Move one hand back and forth.

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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

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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 placed on your machine as a guide for your safety and for those working with you. Walk around the machine and note the content and location of these safety signs before operating your machine. Keep safety signs clean and legible. Clean safety signs with a soft cloth, water, and a gentle detergent. 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 that is replaced, make sure the safety sign is installed on the new part. See your dealer for replacement safety signs.

Safety signs that display the “Read Operator’s Manual” symbol are intended to direct the operator to the operator’s manual for further information regarding maintenance, adjustments, or procedures for particular areas of the machine.

2-30

2 - SAFETY INFORMATION

RAIL14COM0380HA

1

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

2-31

2 - SAFETY INFORMATION

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

RAIL14COM0180AA

2

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3

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4

2. Wear safety belt 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

2-32

2 - SAFETY INFORMATION

4. Danger zone Keep a safe distance.

Location: On the rear rail, on the left and on the right on the front frame

RAIL14COM0182AA

5

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6

RAIL14COM0168AA

7

5. Danger zone (Optional) Keep a safe distance from the edge cutter and compactor 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

2-33

2 - SAFETY INFORMATION

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

Location: Left door of the engine compartment

RAIL14COM0166AA

8

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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

2-34

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

2-35

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

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15

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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

2-36

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

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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

2-37

2 - SAFETY INFORMATION

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

RAIL14COM0796AA

2-38

20

3 - CONTROLS AND INSTRUMENTS

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

Access to operator's platform 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

DV209C - DV210C compactor is provided with foldable steps. Illustrations provided in this manual show the steps in usable (unfolded) position for clarity.

Steps in folded position

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1

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2

Steps in usable position

3-1

3 - CONTROLS AND INSTRUMENTS

• 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.

3-2

3

3 - CONTROLS AND INSTRUMENTS

Operator's seat

Operator seat 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. Backrest position 4. Backrest position 5. Seat springing stiffness according to weight indicator.

6. Seat cross motion NOTICE: Open the window before setting the seat in the final cross position After the lever (6) is lifted and the switch (7) pressed, the seat can be set to the final cross position.

RAIL14COM0215AA

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.

3-3

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.

3-4

3 - CONTROLS AND INSTRUMENTS

Forward controls

Steering column Use the lever (A) to control the steering column tilting forward or rearward.

Use the lever (B) to adjust the steering wheel up or down.

RAIL14COM0179BA

3-5

1

3 - CONTROLS AND INSTRUMENTS

Left-hand side controls

Left-hand side controls

RAIL14COM0374HA

3-6

1

3 - CONTROLS AND INSTRUMENTS

1.

– Pumps sprinkling selector switch:

4.

• Select one of the two drum sprinkling pumps.

• It is used for turning on the edge cutter (final compactor).

• The pump operation is indicated on the display.

• The selector switch has three positions: Left – Left edge cutter/final compactor Center - Off Right – Right edge cutter/final compactor

• The selector switch has three positions: 1 – 1st pump On 0 – Off 2 – 2nd pump On

2.

– Edge cutter selection switch:

5.

– Sprinkling button:

– Drum vibration selector switch: • The selector switch has three positions: Left - Front drum vibrates Center - both drums vibrate Right - Rear drum vibrates

• Hold the button to enable the drum sprinkling function.

• The function is displayed on the display.

6. Not used – Emulsion sprinkling button (Only

3. wheel version): • Not used

3-7

3 - CONTROLS AND INSTRUMENTS

Right-hand side controls

Right-hand side controls

RAIL14COM0374HA

3-8

1

3 - CONTROLS AND INSTRUMENTS

1.

7.

– Travel controller:

• This switch has two positions: Left - Amplitude II switched On Right - Amplitude I switched On

• 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 0 - zero position - the engine working speed is adjusted F - Forward travel R - Reverse travel

8.

2.

– CRAB mode switches: • To set the drums in the CRAB mode, use the switches on the travel control: Crab mode – Right Crab mode – Left

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

9.

– Turn indicators switch

10.

– Warning horn button

11.

• Press both the switches (2A) and (2B) to set the drums to the starting position

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

– Edge cutter up: • Use this switch to move the edge cutter to the transport position.

4.

12.

• 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.

13.

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

• The vibration function is displayed on the display

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

– Edge cutter down: • Press the switch to move the edge cutter to the working position.

14.

6.

– Hazard light switch

– Vibration switch: • To turn on/off the vibration function, press the switch.

5.

– Emergency brake pushbutton • Press the switch to enable the machine emergency brake.

• The function is displayed on the display

3.

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

• The machine braking is indicated by lighting up the brake indicator lamp on the display.

• The travel speed corresponds to the displacement of the travel controller from the zero position ( 0).

– Vibration amplitude switch

– Seat stop switch:

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

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

3-9

3 - CONTROLS AND INSTRUMENTS

16. Ignition box 15.

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

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

• Ignition box has three positions 0 - Ignition Off I - Ignition On II - Crank Engine • The key can be inserted and removed in position 0 only.

• Turn the key to right-hand side to select position I and position II. • Position II is used to start the engine.

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3 - CONTROLS AND INSTRUMENTS

Rearward controls

Rearward controls 1.

– ACE Force Control Unit External connector • It is used for connecting a laptop to the control unit of the ACE Force system to troubleshoot and set parameters.

2.

– CAN1 Connector • Connector for the machine control unit CANBUS connection.

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

3.

RAIL14COM0203AA

1

RAIL14COM0205AA

2

– CAN2 Connector • Connector for the machine control unit CANBUS connection.

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

4.

5.

– 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.

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

6. 24 V Power socket • It is used for connecting a lamp or other equipment.

3-11

3 - CONTROLS AND INSTRUMENTS

Fuse box 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

10 A 10 A

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

RAIL14COM0203AA

3-12

3

3 - CONTROLS AND INSTRUMENTS

Overhead controls

Overhead controls

RAIL14COM0305FA

1

Rear window heating switch 4.

1.

• It is used to switch On/Off the rotating beacon. Indicator lamp in this switch signals this function.

– Glass washer switch • This switch has three positions: – Window washing On – Off – Rear window washing On

– Rotating beacon switch (Optional)

5.

– Cab additional lights switch • It is used to switch ON/OFF additional lights. Indicator lamp in this switch signals this function.

2.

– Front wiper selector switch • This switch has three positions: – Turned Off Low speed On High speed On

3.

6.

– Cabin lighting

7. Radio (Optional equipment) 8. Rear mirror NOTICE: Maintain the mirrors clean and properly adjusted!

– Rear wiper selector switch • This switch has three positions: – Turned Off Low speed On High speed On

3-13

3 - CONTROLS AND INSTRUMENTS

Exterior controls

Exterior controls Control lever It is used for controlling the hand pump for releasing the machine brakes.

RAIL14COM0208AA

1

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2

Battery master switch 1. This switch is used to disconnect the battery from the Machine.

• This switch has two positions: Position 0 – Machine wiring disconnected Position 1 – Machine wiring connected.

2. Engine compartment fuse box The following fuses are available in the engine compartment fuse box (2).

F25 F26 F27 F31 F32 F33 F34 F36 F37

20 A 5A 5A 80 A 15 A 10 A 15 A 125 A 30 A

Rear window heating Front working lights Rear working lights Main fuse Air-conditioning Fuel pump Auto-radio (memory) Pre-heating Engine electronics

NOTICE: Always replace the fuses with the ones of identical value.

3-14

3 - CONTROLS AND INSTRUMENTS

Display

Display 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

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1

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2

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

Use this pin number 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. There are two PIN cards supplied with the machine.

In the event of the PIN card loss, contact your dealer or CASE CONSTRUCTION customer care.

3-15

3 - CONTROLS AND INSTRUMENTS

Enter the PIN when prompted.

To enter the PIN use the display buttons. Each button corresponds to a number. Refer to the image for reference.

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 Page 3-17.

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.

3-16

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 option can be selected by pressing the leftupper selection button.

• Use this option to set the maximum engine speed in rpm (Nominal engine speed should be 2200 RPM)

—

– Vibration frequency

• Use this option 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 specifications table in Page 8-1 for the operating frequencies.

2.

– Drum sprinkling • Use this option 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 reduce and left-lower selection button to increase the sprinkling intensity.

3-17

3 - CONTROLS AND INSTRUMENTS

5.

4.

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

– Travel speed • Use this option 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 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)

– Differential lock

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)

• This option 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.

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

• Use the right-lower selection button to reduce and right-middle selection button to increase the speed gears.

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

NOTE: The speed gear 0 is set as starting gear after 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.

3-18

3 - CONTROLS AND INSTRUMENTS

Operations screen – Notifications

RAIL14COM0314AA

1.

6.

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

2.

2

– 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).

– Indicator lamps of turn indicators • These indicators show that the turn indicators are On

7.

– Machine extended track indicator (Crab) • This indicator shows the drum settings.

3.

– Infra thermometer indicator (Optional)

• Range: 0 - 170 mm (0 - 6.7 in)

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

8.

4.

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

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

9.

5.

– Vibration gauge

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

3-19

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

3 - CONTROLS AND INSTRUMENTS

RAIL14COM0315AA

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 stall - the machine will stop and the parking brake will be enabled.

• If this indicator appears, the engine will stall - 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.

– Coolant level indicator 4.

• This indicator indicates low coolant level.

• If this indicator appears, the engine will stall - 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.

3-20

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

• If this indicator appears, the engine will stall - 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 indicator and an audible signal indicate a error on the control unit.

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

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

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

6.

• 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.

– Air filter clogging indicator

• If the error occurs repeatedly, shut down the machine and call the service. For easier communication with the service, 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.

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

NOTICE: If this indication appears on the screen, stop the machine and replace the filter cartridge immediately.

7.

12.

– Hydraulic oil filter clogging indicator

NOTICE: If this indicator appears, clean the coarse fuel filter.

• When “1” appears on the indicator it indicates that the main filter is clogged.

13.

NOTICE: If this indicator appears, immediately replace the cartridge!

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

14.

– Parking brake indicator

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

• This indicator indicates that the parking brake is enabled.

10.

– Fuel filter indicator • This indicator indicates that the filter cartridge is clogged.

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

9.

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

• This indicator indicates that the filter cartridge is clogged.

8.

– Master caution indicator

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

– ROPS2D (Optional) • This flashing indicator and the audible alarm inform about the dangerous inclination of the machine when the roller moves crosswise in a slope, at the same time the vibration is interrupted - there is a danger of slide-slipping.

NOTICE: The vibration cannot be turned on, until the machine returns to a safe angle of travel.

15.

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

16.

– Diesel Exhaust Fluid level (DEF): Not used

17.

– Exhaust temperature high: Not used

18.

– Diesel Particulate filter (DPF): Not used

3-21

3 - CONTROLS AND INSTRUMENTS

Information screen

RAIL14COM0306FA

1.

6.

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

– Vibration frequency indicator

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

• This field indicates the vibration frequencies of the front and rear drum. 0 Hz indicates that the vibrations are turned Off. 8.

3.

– Tachometer • This field indicates the engine speed in rpm.

7.

2.

4

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

– Brake test control

– Worked hours indicator -

4. amplitude II

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

5.

9.

• This field indicates the battery voltage

10.

– Worked hours indicator -

– Battery voltage indicator

amplitude I

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

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

3-22

3 - CONTROLS AND INSTRUMENTS

11.

14.

– Engine lubrication pressure

• This field indicates the engine coolant temperature.

• This field shows the engine oil pressure.

12.

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

13.

– Coolant temperature indicator

15.

– Hydraulic oil temperature indicator • This field 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 screens

RAIL14COM0308FA

5

1.

– Extended track button (CRAB) - right

9.

– Manual water sprinkling button

2.

– Edge cutter button - down

10.

– Not used

3.

– Vibration button

11.

– Indication switch of hydraulic oil filter clogging

4.

5.

6.

7.

8.

– Edge cutter button - up 12.

– Hydraulic oil level switch

13.

– Amplitude I sensor

14.

– Amplitude II sensor

15.

– Manual vibration sensor

16.

– Automatic vibration sensor

– Neutral sensor

– Brake sensor

– Sprinkling pump switch 1

– Sprinkling pump switch 2

3-24

3 - CONTROLS AND INSTRUMENTS

17.

– Drum vibration sensor

22.

– Service switch

18.

– Not used

23.

– Extended track button (CRAB) - left

19.

– Emergency brake switch

24.

– Edge cutter switch - right

20.

– Not assigned

25.

– Edge cutter switch - left

21.

– Seat switch

3-25

3 - CONTROLS AND INSTRUMENTS

RAIL14COM0316FA

1.

— rearward

– Travel lever sensor - forward,

2.

– Crab sensor

3.

– Infra-thermometer switch (Optional)

4.

– Not used

5.

– Water level sensor

6.

– Fuel level sensor

7.

– Display error messages

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

3-26

3 - CONTROLS AND INSTRUMENTS

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

This function 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 3-15 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 Off.

3-27

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1

RAIL14COM0378AA

2

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.

RAIL14COM0299AA

1

RAIL14COM0378AA

2

• 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 3-15 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

RAIL14COM0296AA

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 filer (2) contains replaceable cartridges, which filters the impurities from the air.

3-30

RAIL14COM0204AA

2

3 - CONTROLS AND INSTRUMENTS

CAB CONTROLS AND ADJUSTMENTS

Cab - Control identification Fire extinguisher (Optional) Place the fire extinguisher in the location indicated.

NOTICE: The manufacturer recommends that the machine should be equipped with a fire extinguisher.

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1

RAIL14COM0207AA

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4

Window washer tank Contact your dealer for the correct fluid to be used.

NOTICE: If water is used, fill antifreeze or drain when operating the machine in cold weather.

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

First-aid box stowage place Place the first aid box in the location indicated.

NOTICE: The machine should be equipped with a first aid box.

3-31

3 - CONTROLS AND INSTRUMENTS

3-32

4 - OPERATING INSTRUCTIONS

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

De-conservation and inspection of brand new machines NOTICE: Remove conservation and wash the machine in places with drain collectors available to collect rinsed water and chemicals.

Check the machine against the delivery documentation.

Check whether any parts were damaged during transport or are missing. Inform the shipper of any discrepancies.

Before starting operations again, wash off conservation with pressurized hot water (hot water should be mixed with ordinary de-greasing agents added as directed).

NOTICE: Follow environmental and ecology rules while using the de-greasing agent.

4-1

4 - OPERATING INSTRUCTIONS

Operating the machine during running-in period 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!

4-2

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

Check daily before engine starting the amount of oil in the engine and hydraulic tank, cooling liquid in the cooling circuit, fuel in fuel tank, water level in water tank. Confirm no loosened, worn or missing parts exist on the Machine.

Check the following 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.

4-3

4 - OPERATING INSTRUCTIONS

RAIL14COM0375AA

1

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4-4

4 - OPERATING INSTRUCTIONS

Start the engine as follows: 1.

Switch ON the battery master 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 Page 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 the 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 I. If the engine does not start even after 3 attempts, check the oil system.

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. When the test is unsuccessful, “TEST NOT OK” appears on the screen. If the test is unsuccessful, contact your dealer immediately.

4-5

4 - OPERATING INSTRUCTIONS

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.

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

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

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

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

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!

4-6

4 - OPERATING INSTRUCTIONS

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!

4-7

4 - OPERATING INSTRUCTIONS

Stopping the unit

Stopping the machine

RAIL14COM0377HA

4-8

1

4 - OPERATING INSTRUCTIONS

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. Switch over the key in the ignition box (3) to position 0, and tilt back the ignition box 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. Turn the battery master switch to Off position.

NOTICE: Switch Off the battery master switch only after 60 seconds from switching off the ignition key. This time is required for the Engine controller (ECM) to save the data.

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 lights up on the display (5).

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.

4-9

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

4-10

4 - OPERATING INSTRUCTIONS

RAIL14COM0377HA

4-11

1

4 - OPERATING INSTRUCTIONS

Selecting travel direction Start the engine (see Page 4-3).

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)

NOTICE: The speed gear 0 is set as the starting gear after 15 minutes after the ignition box is turned Off.

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

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 through 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 off set press and hold both the buttons (5) and (6).

4-12

4 - OPERATING INSTRUCTIONS

Parking the unit

Machine parking 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 minutes before turning Off. This will help the engine and turbo charger cool slowly and evenly.

NOTICE: Switch Off the battery master switch only after 60 seconds from switching off the ignition key. This time is required for the Engine controller (ECM) to save the data.

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

3. Turn off the battery master 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.

4-13

4 - OPERATING INSTRUCTIONS

4-14

5 - TRANSPORT OPERATIONS

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

Traveling on public roads NOTICE: The standard type of the machine is not intended for driving on public road. When on the road, the machine should be transported on a vehicle. In the unavoidable situation to drive the machine on public roads for shorter distances, follow the below safety precautions.

The Machine may pass by its own axis between its workplaces.

When on the road, the machine should be transported on a vehicle (See Page 5-2 for more information).

5-1

5 - TRANSPORT OPERATIONS

Shipping transport

Machine transport (on a trailer) When on the road, the machine should be transported on a vehicle.

When loading and unloading, the vehicle transporting the machine must be braked and mechanically protected against accidental movement using wheel chocks (3).

The machine on the vehicle must be properly tied (1) and mechanically secured against longitudinal and lateral displacement as well as against tipping. The drums must be secured using wheel chocks (2).

RAIL14COM0279AA

1

RAIL14COM0382AA

2

RAIL14COM0381AA

3

Loading the machine with a ramp Set the scrapers in the working position.

Use a ramp with the following limitations: • L = 3.25 x H • Ramp angel (Φ) should not exceed 18°

Loading the machine with a crane Use loading ramps to load the machine on the transport vehicle.

The machine may also be lifted for loading into the vehicle.

5-2

5 - TRANSPORT OPERATIONS

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

RAIL14COM0210AA

4

RAIL14COM0282AA

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 towing machine should correspond to the size of the towed machine. It must have a sufficient traction force (power), weight and brake effect.

• Do not start the engine when towing.

• When towing downhill using a rope, another towing machine must be connected to the rear part of the damaged machine. Thus it is possible to prevent an uncontrolled movement of the damaged machine.

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, haul the machine for a short distance and continue normal operation 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) RAIL14COM0285AA

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.

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

A decal which explains the towing procedure is placed in the machine. Follow the instructions in the sign and this manual to tow the machine.

5-4

1

5 - TRANSPORT OPERATIONS

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

Use only the towing lugs for towing.

RAIL14COM0280AA

2

RAIL14COM0222AA

3

RAIL14COM0212AA

4

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5

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

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

3. Adjust washer from position A to position B.

5-5

5 - TRANSPORT OPERATIONS

4. Reinstall the lever (2) in original position and move the lever to position C.

RAIL14COM0283AA

6

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7

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8

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9

Machine brake off 5. Remove the lever (3).

6. Adjust washer from position A to position B.

7. Reinstall the lever (3) in original position and move the lever to position D.

5-6

5 - TRANSPORT OPERATIONS

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

RAIL14COM0222AA

10

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11

RAIL14COM0214AA

12

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13

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. 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.

NOTICE: When towing is complete, secure the machine with Chocks and apply the brakes.

5-7

5 - TRANSPORT OPERATIONS

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 (3) to position D. 2. Remove the lever (3).

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14

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15

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16

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17

3. Adjust washer from position B to position A. 4. Reinstall the lever (3).

Removing hydraulic short circuit 5. Move the lever (2) to position E. 6. Remove the lever (2).

7. Adjust washer from position B to position A. 8. Reinstall the lever (1).

5-8

6 - WORKING OPERATIONS

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

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 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 diesel oil.

• 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.

6-1

6 - WORKING OPERATIONS

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 At ambient temperatures when hydraulic oil temperature is constantly around 90 °C (194 °F), the manufacturer recommends to change the hydraulic oil with viscosity of 100 mm²/s.

6-2

6 - WORKING OPERATIONS

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).

6-3

6 - WORKING OPERATIONS

Operating the machine in extremely dusty environment While in very dusty environment:

• Reduce the intervals of cleaning the coolers.

• Reduce the intervals of cleaning and replacing the air filter elements

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

• Reduce the replacement intervals of cabin dust filter

6-4

6 - WORKING OPERATIONS

Compaction

Machine travel and reversing including vibration

RAIL14COM0376AA

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

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

6-5

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.

6-6

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2

RAIL14COM0278AA

3

6 - WORKING OPERATIONS

Sprinkling

RAIL14COM0376AA

1

It is used to sprinkle the Machine drums.

The water level in the tank is displayed on the display.

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 (10), 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 (9) to the center position (Position 0).

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

6-7

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) due to high level of compaction of the background material or travel with vibration on hard materials.

This condition will come to light in the form of increased vibration transfer into Machine frame and onto operator’s

control stand. The vibro-stroke can partly be eliminated through the increased travel speed.

NOTICE: It is banned to work in vibro-stroke mode in the long term! In extreme cases there is Machine damage hazard or operator’s health hazard!

6-8

7 - MAINTENANCE

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

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

Use the torque wrenches to do the 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 (with coefficient of friction = 0.14). These figures do not apply to a lubricated thread.

7-1

7 - MAINTENANCE

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)

7-2

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

7-3

2

7 - MAINTENANCE

Biodiesel fuel Biodiesel usage in CASE CONSTRUCTION products Introduction to Fatty Acid Methyl Ester (FAME) biodiesel 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 20 % biodiesel fuel (B20). 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.

• B5: indicates the blend of 5 % biodiesel and 95 % diesel fuels.

• B7: indicates the blend of 7 % biodiesel and 93 % diesel fuels.

• B20: indicates the blend of 20 % biodiesel and 80 % diesel fuels.

• B100: indicates pure biodiesel, or 100 % biodiesel fuel.

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.

Biodiesel fuel can be used to run diesel engines as pure biodiesel fuel or when blended with standard diesel fuel:

Diesel and biodiesel fuel specifications Tier 4a diesel fuel specifications are covered by the following: • ASTM D975-10, Standard Specification for Diesel Fuel Oils. (15 ppm sulfur maximum.)

Biodiesel blends are covered by: • United States Diesel Fuel Specification ASTM D6751-09A allows up to 5 % biodiesel since 2009.

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

• United States Biodiesel Fuel Specification ASTM D7467-09A provides specifications for diesel and biodiesel blends from B5 to B20.

Pure biodiesel (B100) specification is covered by the following requirements: • ASTM D6751-09A - 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 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.

7-4

7 - MAINTENANCE

Biodiesel fuel usage conditions 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.

The main concerns related to operation with biodiesel fuels are:

For machines using Tier 4a engines with an exhaust aftertreatment system: 1. If the biodiesel blend stock to ASTM D6751-09A is used, special precautions need to be taken to insure that it fully complies with the following special requirements: • Group I Metals content (Sodium + Potassium) is ≤ 5 mg/kg per EN14538 as specified in the biodiesel spec.

• Filters and injector blockage caused by poor fuel quality.

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

• Group II Metals content (Calcium + Magnesium) is ≤ 5 mg/kg per EN14538 as specified in the biodiesel spec.

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

• Phosphorus content lower than specified is a mandatory requirement. Phosphorus must not exceed 4 mg/kg per ASTM D4951.

• 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.

2. The resulting greater than B5 through B20 blend must not exceed 1 mg/kg for Group I Metals (Sodium + Potassium) and for Group II Metals (Calcium + Magnesium).

NOTICE: For machines using Tier 4a engines with an exhaust aftertreatment system in regions where the biodiesel blend stock is supplied to the ASTM D6751-09A standard, it is essential that evidence of compliance to the special limits for Group I Metals, Group II Metals and the reduced phosphorus content specified above be obtained on every delivery of fuel from the fuel supplier. Failure to comply with this requirement can result in damage to the catalyst of the aftertreatment system which will not be covered under warranty.

Purchase biodiesel fuel from a trusted supplier who understands the product and maintains acceptable fuel quality. It is highly recommended that you use biodiesel from BQ 9000 accredited suppliers to maintain the quality and consistency of the fuel. The BQ 9000 Quality Management Program is accredited by the National Biodiesel Board for producers and marketers of biodiesel fuel. See the National Biodiesel Board website at www.biodiesel.org for more information.

The use of biodiesel blends above B5 through B20 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.

Maintenance intervals For machines using the all electronic engines with a high pressure common rail fuel system, the engine oil and filter change interval is reduced to 250 h when using biodiesel blends greater than B5 up to B20. Please refer to the maintenance intervals specified in the Operator Manual for all engines.

Check all hoses, connections and gaskets to ensure integrity and cleanliness every 3 months or 150 hours of operation, whichever comes first.

Regular oil sampling is highly recommended to monitor for oil and engine deterioration.

NOTE: Oil sampling kits are available from your authorized CASE CONSTRUCTION dealer.

When switching back from biodiesel to regular #2 diesel, all fuel filter, oil and oil filter should be changed even if this falls between routine service intervals.

Storage The machine should not be stored for more than three months with biodiesel in the fuel system. For longer stor-

age time, it is strongly suggested that only regular #2 diesel fuel is used.

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7 - MAINTENANCE

NOTE: If storage for longer than 3 months is necessary, the engine must be run on regular #2 diesel for a minimum of 20 h to flush the biodiesel fuel out of the fuel system prior to storage.

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.

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

NOTICE: Do not use biocide additives on Tier 4a engines with an exhaust aftertreatment system.

7-6

7 - MAINTENANCE

Fluids and lubricants NOTICE: While any company can perform the necessary maintenance or repairs on your equipment, CASE CONSTRUCTION strongly recommends that you use only CASE CONSTRUCTION dealers and products that meet given specifications. Improperly or incorrectly performed maintenance and repair voids the equipment warranty and may affect service intervals.

CASE CONINTERNATIONAL STRUCRECOMMENDED FLUIDS Specifications TIONSpecifiAND APPLICATION cations CASE SAE 10W40 AKCELA API CJ-4 ENGINE - OIL UNITEK ACEA E9 10W-40 COOLING SYSTEM CNH XHD CNH XHD HEAVY DUTY HEAVY DUTY ASTM D6210 Type COOLANT / ANTI-FREEZE COOLANT / 1-FF ANTI-FREEZE antifreeze 50% water 50% CASE DIN 51524 PART 3 AKCELA API GL-4 NEXHYDRAULIC SYSTEM ISO VG-32/46 PLORE™ SAE 10W30 FLUID FUEL TANK Ultra Low Sulfur Diesel (ULSD) SAE ASTM EN590 Decanted and filtered diesel ASTM D975 S15 fuel (Sulfur not exceeding 15 mg/kg) TUTELA STEERING JOINT MULTI BEARINGS, YOKE PURPOSE BEARINGS, STEERING NLGI 2 EP GREASE SWIVEL PINS, 251H, GR-9 SUSPENSIONS: CASE SAE 10W40 AKCELA VIBRATION DRUM API CJ-4 UNITEK ACEA E9 10W-40 TUTELA HYPOIDE EP GEAR LUBE SAE 80W-90 API GL-5 or DRUM DRIVE REDUCER MIL-L-2105 D TUTELA HYPOIDE EP GEAR LUBE SAE 85W-140 – water GLASS WASHER TANK SPRINKLING TANK

Water

–

MODELS

QUANTITY

ALL

9 L (2.38 US gal)

ALL

23 L (6.08 US gal)

ALL

60 L (15.85 US gal)

ALL

210 L (55.48 US gal)

ALL

As required

ALL

2 X 10.5 L (2.77 US gal)

ALL

2 x 2 L (0.53 US gal)

ALL

2.75 L (0.73 US gal) 840 L (221.90 US gal) 2 X 100 L (26.42 US gal)

ALL ALL

DRUM COOLING LIQUID AIR-CONDITIONING SYSTEM

-

—

ALL

AIR-CONDITIONING COMPRESSOR

CNH PAG OIL or PAG SP20

–

ALL

7-7

0.3 L (0.08 US gal)

7 - MAINTENANCE

Engine oil viscosity — Recommended operating temperature range Engine oil has been specified as per its performance classification and viscosity classification.

Performance classification Considering emission requirements for Tier 4 interim, CASE CONSTRUCTION requires so that only oils certificated

by CASE CONSTRUCTION and engine manufacturers are used.

You can find the engine manufacturers recommended list of engine oils at the website of the engine manufacturer Deutz (www. deutz.com).

Viscosity classification To determine SAE (Society of Automotive Engineers) viscosity class, the ambient temperature and type of operation in place of usage of the machine are decisive.

NOTE: Exceeding of the lower temperature limit does not damage the engine, it may only cause starting problems.

Use the below table as a reference while selecting the correct engine oil for your machine. Contact your dealer for any information.

CJ-4 Oils – Tier 4i emissions equipped machines

(H)

0W-40 CJ-4 UNITEK to MAT3521

(H)

API CJ–4 0W-40 (H)

10W-40 CJ-4 UNITEK to CNH MAT3521

(H)

API CJ–4 10W-40 (H)

15W-40 CJ-4 UNITEK to CNH MAT3521

(H)

-40 °C -40 °F

-30 °C -22 °F

-20 °C -4 °F

-10 °C 14 °F

API CJ–4 15W-40

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) Engine oil pan or coolant block heater recommended in this range NOTICE: Reduce the engine oil change frequency to half if the engine needs to be operated below -10 °C (14 °F) or if the engine oil temperature remains below 60 °C (140 °F) during the machine operation.

7-8

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 box, and disconnect the wiring (unless otherwise required).

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1

Engine oil

Grease

Hydraulic oil

Transmission oil

Top up

Grease

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

RAIL14COM0306FA

7-9

2

7 - MAINTENANCE

Removed or loose bolts, plugs, threaded joints of the hydraulics, etc. shall be tightened with the torque according to the charts in Page 7-1, unless a different value is given with the relevant operation.

After the first 200 hours of working with a new machine (or after machine general overhaul), change the gearbox oil as explained in Page 7-53.

7-10

7 - MAINTENANCE

Maintenance planning

Maintenance chart Change fluid Grease Cleaning Level make up Check

Replace Test Bleed Drain fluid Adjust

Maintenance action Every 20 hours of operation or daily Engine oil level 7-13 Engine 7-14 Engine coolant level 7-15 7-16 Air filter vacuum valve 7-17 Cooling fan Fuel tank level 7-18 Hydraulic oil level 7-19 Water tank 7-20 7-21 Controls and alarms 7-23 Gearbox Air-conditioning compressor drive belt 7-24 Exhaust system leaks 7-25 Every 250 hours of operation or every 3 months 7-26 Water filter 7-28 Grease points Every 500 hours of operation or every 6 months Engine accessory drive belt 7-31 Engine oil 7-32 7-35 Intake manifold 7-36 Air filter sensor Engine coolant level 7-37 Wiring 7-38 7-39 Water Separator 7-40 Air-conditioning refrigerant level 7-41 Air-conditioning system filters 7-42 Engine fuel filter 7-46 Engine air filter Every 1000 hours of operation or annually Engine cooling system 7-49 Battery 7-50 Engine belts 7-52 7-53 Gearbox oil Vibrations system oil 7-54 7-55 Suspension and silencing system 7-57 Water tank 7-58 Water / Oil / Intercooler Radiator Engine 7-59 7-60 Engine and machine control modules/control units Air-conditioning compressor drive belt 7-61 Air-conditioning compressor mounting 7-63 7-64 Hydraulic oil and filters Every 2000 hours of operation or every 2 years Engine coolant 7-68 As required Fuel system 7-71 7-11

Page no.

7 - MAINTENANCE

Change fluid Grease Cleaning Level make up Check Maintenance action Water / Oil / Intercooler Radiator Cab ventilation air filter Drain water from the sprinkling circuit before winter season Scrapers Machine cleaning

Replace Test Bleed Drain fluid Adjust Page no.

7-72 7-73 7-74 7-76 7-77

7-12

7 - MAINTENANCE

Every 20 hours of operation or daily

Engine oil level 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.

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2

4. Low division mark MIN shows lowest possible oil level, high division mark MAX 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 and capacity 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 7-8.

Engine oil capacity: 9 L (2.38 US gal)

7-13

7 - MAINTENANCE

Engine - Check for 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.

RAIL14COM0218AA

7-14

1

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

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.

SS12C364

1

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2

4. In case of high coolant loss, find out any cooling system leakage and rectify the problem.

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% Capacity: 23 L (6.08 US gal)

7-15

7 - MAINTENANCE

Air filter vacuum valve 1. To clean the air filter vacuum 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 vacuum valve is damaged, replace it with new one.

RAIL14COM0222AA

7-16

1

7 - MAINTENANCE

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.

RAIL14COM0225AC

7-17

1

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

Check the fuel quantity on the display. If necessary, refill as follows:

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1

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2

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

Fuel specification and capacity: Use decanted and filtered Ultra Low Sulfur Diesel (ULSD) fuel only.

NOTE: The sulfur content should not exceed 15 mg/kg.

Fuel tank capacity: 210 L (55.48 US gal)

7-18

7 - MAINTENANCE

Hydraulic oil level 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.

RAIL14COM0218AA

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.

Capacity: Hydraulic systems: 60 L (15.85 US gal)

7-19

1

7 - MAINTENANCE

Water tank 1. Check the water quantity on the display and refill if need.

RAIL14COM0286AA

1

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2

2. Open the cap (1) and refill with clean water via the strainer (2).

NOTICE: Before winter period, refer to Page 7-74 and drain water from the water tank and sprinkling system.

Fluid specification and capacity • Fluid: Water • Capacity: 840 L (221.9 US gal)

7-20

7 - MAINTENANCE

Controls and alarms 1. Turn the ignition key to position I.

RAIL14COM0274AA

1

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2

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3

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4

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.

Warning lights button

4.

Lights switch (parking/dipped) (optional)

5.

Rear lights switch (optional)

6.

Additional lights switch (optional)

7.

Warning beacon switch

7-21

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

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6

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7

5. The charging indicator lamps (1) must go out after the starting is completed.

6. Start moving the Machine.

7. After the machine starts moving, the brake indicator (1) lamp must goes out.

Emergency brake function 1. Start moving the machine at low speed.

1.

Use sound signal to indicate the engine start!

2.

Before engine is started, check there is no hazard of any person if engine is started!

3.

Use sound signal before Machine starts moving and wait long enough to any persons present can leave the area round the Machine (space beneath the Machine) in time!

4.

Make sure the area in front and behind the Machine is free, with no persons present within thereof!

2. Press the emergency brake button (1).

3. The machine will stop, the parking brake will be enabled and the engine will stall.

4. The brake indicator lamp lights up on the display.

5. Move the travel control (2) to the brake position (P).

Turn the ignition key to the position 0.

6. Now you can start the engine again.

NOTE: During operation, check continuously the instruments and indicator lamps.

7-22

7 - MAINTENANCE

Gearbox 1. Check the gearboxes visually for oil leaks.

2. If there are any oil leaks, find the cause for the leak and rectify.

RAIL14COM0226AA

7-23

1

7 - MAINTENANCE

Air-conditioning compressor drive belt 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.

RAIL14COM0230AA

7-24

1

7 - MAINTENANCE

Exhaust system leaks 1. Check clips and pipings of the exhaust system.

2. If there are any leaks, find the cause for the leak and rectify.

NOTICE: If the exhaust pipe with a flexible part between the engine and the catalytic converter shows any leak or damage, the machine cannot be operated until the defect is fixed.

RAIL14COM0223AA

7-25

1

7 - MAINTENANCE

Every 250 hours of operation or every 3 months

Water filter 1. Close water supply through the valve (1).

2. Remove sprinkler filter vessel (2), replace the strainer (3) and clean it.

3. Check the O-ring (4). Replace if damaged.

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1

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2

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3

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4

4. Remove the sprinklers (5).

5. Remove and clean sprinkler strainers (6).

7-26

7 - MAINTENANCE

6. Remove valves and clean diaphragms (7).

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5

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6

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7

7. Remove the sprinklers (8).

8. Remove and clean the sprinkler strainers (9).

7-27

7 - MAINTENANCE

Grease points 1. Take off the caps on the greasing points.

2. Pump the new grease into the grease fittings with a high-pressure press until the old grease starts pouring out.

3. Reinstall the greasing point caps.

Steering joint Number of greasing points: 2

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7-28

1

7 - MAINTENANCE

Steering cylinder Number of greasing points: 4

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2

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3

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4

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5

Edge cutter cylinder Number of greasing points: 2

7-29

7 - MAINTENANCE

Cab door hinges Number of greasing points: 4

RAIL14COM0258AA

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.

7-30

6

7 - MAINTENANCE

Every 500 hours of operation or every 6 months

Engine accessory drive belt 1. Visually check the belt (1) for sign of wear and damages. Cracks perpendicular to the belt width are not considered a damage.

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1

SS12C368

2

2. Replace the belt if there are longitudinal cracks, shattered edges or protruding materials on the belt.

7-31

7 - MAINTENANCE

Engine oil 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

1. Use a suitable container of adequate capacity to collect the drained engine oil.

NOTE: The volume of drained engine oil will be approx.

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.

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7 - MAINTENANCE

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.

SS12C389

4

SS12C390

5

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6

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7

7. Manually tighten the filter cartridge (4) until the seal (3) touches the support. With the oil filter wrench, tighten the filter cartridge (4) till the seal (3) is compressed as shown in the image (Approximate torque: 17 - 18 N·m (12.5 - 13.3 lb ft)).

NOTICE: Do not overtighten the filter, the thread and gasket may get damaged.

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.

7-33

7 - MAINTENANCE

Oil specification and capacity 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 7-8.

Engine oil capacity: 9 L (2.38 US gal)

7-34

7 - MAINTENANCE

Intake manifold - Check 1. Check the hoses (1) and clamps (2).

2. Replace the damaged clamps (2) or hoses (1) before operating the machine.

7-35

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7 - MAINTENANCE

Air filter sensor 1. 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

2. Cover the air suction hole (1).

NOTICE: Do not use objects like thin paper to cover it, paper may get sucked in and clog the intake.

3. Once covered, the indicator lamp (1) for air filter clogged should come On in the display.

4. If the indicator does not go ON, check the vacuum switch (1), contacts and feeder cables (2).

7-36

7 - MAINTENANCE

Engine coolant level 1. Check the concentration via refractometer (1).

2. If the concentration for -36 °C (-33 °F) has not been measured, adjust the concentration by adding antifreeze into the cooling system.

SS12D505

7-37

1

7 - MAINTENANCE

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.

7-38

7 - MAINTENANCE

Water Separator 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 separator when the engine is running.

RAIL14COM0327AA

7-39

1

7 - MAINTENANCE

Air-conditioning refrigerant level 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. Lift the engine hood. Check the filter dehydrator sight hole while the air-conditioning system is on and the engine is running at idle speed.

2. The liquid flowing in the sight gauge (1) must be transparent.

3. Fogging or foam indicates the lack of coolant and causes decreased unit functionality. Check the hoses, their-connections and the compressor for coolant leaks.

4. To remove any defects, consult your dealer.

RAIL14COM0320AA

7-40

1

7 - MAINTENANCE

Air-conditioning system filters 1. Remove the cover grille (1) on both sides.

2. Replace both filter elements.

3. Beat the elements gently and wash them in a detergent solution. Should any element be damaged or should it not be possible to remove dirt, replace it with a new one.

4. In case of operation in highly dusty environment, shorten the intervals of cleaning.

RAIL14COM0261AA

7-41

1

7 - MAINTENANCE

Engine fuel 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. Close fuel tank valves (1).

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SS12C385

3

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 sealing face of filter holder.

7-42

7 - MAINTENANCE

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.

SS12C389

4

SS12C390

5

7. Manually tighten the filter cartridge (4) until the seal (3) touches the support. With the oil filter wrench, tighten the filter cartridge (4) till the seal (3) is compressed as shown in the image (Approximate torque: 17 - 18 N·m (12.5 - 13.3 lb ft)).

Fuel specification and capacity: Use decanted and filtered Ultra Low Sulfur Diesel (ULSD) fuel only.

NOTE: The sulfur content should not exceed 15 mg/kg.

Fuel tank capacity: 210 L (55.48 US gal)

7-43

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 sealing surface of the filter holder.

RAIL14COM0327AA

6

SS12C389

7

SS12C390

8

RAIL14COM0237AA

9

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. With the oil filter wrench, tighten the filter cartridge (4) till the seal (3) is compressed as shown in the image (Approximate torque: 17 - 18 N·m (12.5 - 13.3 lb ft)).

8. Connect the sensor connector.

9. Open fuel tank valves (1).

10. See Page 7-71 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.

7-44

7 - MAINTENANCE

Fuel specification and capacity: Use decanted and filtered Ultra Low Sulfur Diesel (ULSD) fuel only.

NOTE: The sulfur content should not exceed 15 mg/kg.

Fuel tank capacity: 210 L (55.48 US gal)

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 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 safety 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.

Procedure for correct filter element replacement: 1. Slowly pull out the clogged element as carefully as possible.

2. Always clean the inner bodies of the cleaner in a way to avoid dust penetrating inside the engine feed piping.

3. Clean the seating faces for gasket in the cleaner body.

4. Examine the dust traces in the element removed, any traces would be an indication of its leakage in the filter body.

5. Press the gasket on the new element, whether it is flexible.

6. Make sure the gasket is seated properly.

7. The air filter comprises the main element and safety element.

8. Replace the main element always when the air filter clogged indicator (1) goes On in the display.

9. Replace the safety element always after every three replacements of the main element.

10. Confirm the fixing and integrity of the air filter and intake piping.

RAIL14COM0291AA

7-46

1

7 - MAINTENANCE

11. Remove filter cap (2).

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2

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3

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5

12. Remove the main filter element (4) from the filter cover (3).

13. Replace the safety element (5) from the filter cover (3) and check it.

14. Replace the safety element (5) always after every three replacements of the main element.

15. Clean the inner surface of the filter cover (3) taking care to avoid any dust penetration into the inner feed pipe (6).

7-47

7 - MAINTENANCE

16. Clean the air filter vacuum valve (7) and reinstall.

NOTICE: Replace the vacuum filter valve (7) if it is damaged.

RAIL14COM0222AA

7-48

6

7 - MAINTENANCE

Every 1000 hours of operation or annually

Engine cooling system 1. Check the cooling circuit leaks, tighten the loose connections if necessary.

2. Make sure that no hoses (1) are damaged and no clamps (2) 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 7-72.

7-49

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1

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2

SS12C397

3

7 - MAINTENANCE

Battery Follows 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 max amount of milk, water or solution of calcined magnesia in water.

5. Upon skin contact with electrolyte remove contaminated clothing, including shoes, wash affected spots as soon as possible with soap water or solution of soda and water. Get prompt medical attention.

6. Do not eat, drink, smoke, while at work!

7. Having finished the work, wash your hands and your face thoroughly with water and soap!

8. Do not try whether wires are energized through contacting Machine frame.

9. Keep the battery dry and clean.

10. Recharge the undercharged battery.

11. Recharge the battery off the Machine.

12. Never disconnect the battery with the engine running.

13. Follow the battery manufacturer’s manual when working with the battery!

14. Disconnect the battery during its repair, or when handling the wires and electric devices within the wiring circuit to avoid any short circuit.

15. To disconnect the battery you must first disconnect (–) pole of the cable. To connect, first connect (+) pole.

16. Never make direct conductive connection between the battery’s both poles, short circuit will occur with the risk of battery explosion.

17. Do not turn the battery upside down, electrolyte may pour down.

18. Flush spilled electrolyte with water and neutralize with lime.

19. Hand over the aged battery that does not work, for its disposal.

7-50

7 - MAINTENANCE

1. Stop the engine and turn the battery master switch (1) to Off position.

RAIL14COM0222AA

1

RAIL14COM0238AA

2

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. If a maintenance-free battery is installed on the machine, it is not necessary to check the electrolyte level and the electrolyte is not filled up 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 when the acid concentration drops to 1.23 kg/dm3 (77 lb/foot3).

• Keep the outside of the batteries clean and dry.

7-51

7 - MAINTENANCE

Engine belts 1. Use the parking brake to stop the machine.

2. Remove the engine covers.

3. Check the tightening pulley (1) for correct operation.

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SS12C368

2

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4

4. Check the belt visually.

5. When longitudinal cracks occur on the belt, belt edges are shattered, or extracted parts of material in the belt, the belt must be replaced.

Engine belt replacement 6. Loosen the bolts and move the compressor.

7. Take out the belt.

8. Lift off the tightening pulley (1) using a lever.

9. Remove the engine belt (2).

10. Install the new belt (2).

11. Reinstall the engine covers.

7-52

7 - MAINTENANCE

Gearbox oil 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 and Capacities • 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 Capacity: 2 L (0.53 US gal)

7-53

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1

7 - MAINTENANCE

Vibrations system oil 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

RAIL14COM0241AA

1

RAIL14COM0240AA

2

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. Remount the plugs and replace the plug seals.

9. Repeat the above steps on the rear drum.

Oil specification and capacity 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 7-8.

Engine oil capacity: 10.5 L (2.77 US gal) per drum

7-54

7 - MAINTENANCE

Suspension and silencing system 1. Check the condition of mounting bushes (1) for the coherence (bond strength) between metal and rubber and the bolt torques.

2. Replace the damaged mounting bushes (1).

Number of drum mounting bushes (1): 2 x 10

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Number of cab mounting bushes (2): 4

7-55

7 - MAINTENANCE

Number of engine mounting bushes (3): 4

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4

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7

Number of battery mounting bushes (4): 8

Number of radiator mounting bushes (5): 4

7-56

7 - MAINTENANCE

Water tank 1. Remove the caps (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).

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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 too high pressure so to avoid its 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 mounting bushes (1) for condition, metal-rubber bond strength and bolt torques. 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

7-59

1

7 - MAINTENANCE

Engine and machine control modules/control units 1. Contact the authorized service center Deutz for carrying out diagnostics of the engine.

2. Contact your dealer for carrying out diagnostics of the machine.

7-60

7 - MAINTENANCE

Air-conditioning compressor drive belt 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).

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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.

7-61

7 - MAINTENANCE

Air-conditioning belt replacement: 6. Loosen the bolts (1) and move the compressor (2).

7. Remove the damaged belt (3).

8. Install the new belt (3).

RAIL14COM0322AA

7-62

4

7 - MAINTENANCE

Air-conditioning compressor mounting 1. Check the strength of the compressor attachment and the compressor bracket.

RAIL14COM0322AA

7-63

1

7 - MAINTENANCE

Hydraulic oil and filters Follow the below safety precautions before filling the hydraulic fluid: 1. Do NOT open hydraulic tank cover, except for emergency refilling.

2. With the circuit filled, make sure that the hydraulic oil level indicator goes off in the display.

3. Start the engine and with the engine rpm increased, carry out the machine functions (vibrations, sprinkling, crab) to make sure that the hydraulic oil flow through the circuit evenly.

4. Replace the oil and filter element following internal failure of hydraulic components (hydrostatic motors, hydrostatic pumps) or a major overhaul of the hydraulic system.

5. Clean and flush the hydraulic tank and replace filter element whenever a new unit is installed.

6. NEVER use any chemical cleaning agents to clean the hydraulic tank!

7. 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.

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

1. Remove the drain plug (1) and drain the oil on 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

Filling 2. Check the drain plug gasket for condition, replace if necessary. reinstall the filler port

7-64

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7 - MAINTENANCE

3. Open the port and fill up the tank through the filler port (4) till the sight gauge (3) reads MAX.

RAIL14COM0218AA

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.

Capacity: Hydraulic systems: 60 L (15.85 US gal)

7-65

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

SS12C385

5

SS12C389

6

1. Remove the filter.

2. Clean the filer mounting surface with a lint free cloth.

NOTE: DO NOT fill the new filter with fuel before installing it.

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. With the oil filter wrench, tighten the filter cartridge (4) till the seal (3) is compressed as shown in the image (Approximate torque: 17 - 18 N·m (12.5 - 13.3 lb ft)).

7-66

7 - MAINTENANCE

5. Make sure that the hydraulic filter clogged indicator (1) does not goes On in the display.

RAIL14COM0292AA

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.

Capacity: Hydraulic systems: 60 L (15.85 US gal)

7-67

7

7 - MAINTENANCE

Every 2000 hours of operation or every 2 years

Engine coolant 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.

7-68

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 fouled. 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 (3).

13. Make sure that the coolant level is between MIN and MAX markings.

14. Top up the coolant as necessary.

7-69

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% Capacity: 23 L (6.08 US gal)

7-70

7 - MAINTENANCE

As required

Fuel system Bleed the fuel system: 1. When the fuel filters are replaced.

2. When the fuel pump is replaced.

3. After fuel system repair.

4. When the machine is stored for long term.

5. When having run out of fuel from the tank.

Low-pressure piping blow-off and filter bleeding 6. Use a suitable container to drain the fuel.

7. Set the ignition key switch to position I. 8. Loosen the bleed screws (1) on the fuel filter.

9. Bleed the system till bubble free fuel flows out of the bleed screws and tighten the screw.

RAIL14COM0327AA

7-71

1

7 - MAINTENANCE

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 very dusty environment, perform daily cleaning. Cooler fouling will cause a reduced cooling performance and increased temperatures of engine coolant and hydraulic oil.

3. Remove the cover (1).

NOTICE: Do NOT clean the radiator with too high pressure so to avoid its damage.

4. Clean with compressed air or pressure water (steam).

Clean in the direction from the fan side.

NOTE: Follow instructions on detergent packaging.

5. When radiator is contaminated with crude oil products, use an approved detergent to clean the radiator.

7-72

RAIL14COM0225AC

1

7 - MAINTENANCE

Cab ventilation air filter 1. Slide out and remove the filter elements.

2. Beat the element carefully and wash in a detergent solution. If filter element is damaged or cannot be cleaned by detergent, replace it with new one.

3. Clean the filter at least once a month. If the machine operates in dusty environment, reduce the cleaning interval.

RAIL14COM0204AA

7-73

1

7 - MAINTENANCE

Drain water from the sprinkling circuit before winter season 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 vessel (2), filter (3) and O-rings (4).

7-74

7 - MAINTENANCE

4. Leave the valves (5) and (6) open.

RAIL14COM0224AA

4

RAIL14COM0253AA

5

RAIL14COM0255AA

6

RAIL14COM0319AA

7

5. Remove at least one sprinkler 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).

7. To reinstall the removed parts, clean the parts thoroughly and proceed installation in reverse order.

7-75

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

7-76

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. Disconnect the battery master switch.

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!

7-77

7 - MAINTENANCE

Storage

Short term storage Store the machine as follows: • Wash and clean the machine.

• Run the engine till the engine warms up to its operating temperature before storing the machine.

• Park the machine on a firm, level surface at a safe 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 of the controls, etc.

• Drain the water tank (See Page 7-74).

• Check for the required antifreeze properties of the coolant.

• Check the battery charge and recharge if necessary.

• Apply protective coating over the chrome finished surfaces and piston rods.

• Protect the machine against corrosion by spraying the 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

7-78

7 - MAINTENANCE

Machine preservation and storage for longer than 2 month For long term storage (more than 2 months), follow the procedure mentioned in short-term storage (see 7-78) and follows the additional steps provided below: • Remove pressure from the accumulators. Remove from the machine, check their condition and store the parts in a cool dry place.

• Support the machine structurally to avoid damage to the damping system.

• 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.

Before putting back the machine in service, wash the preservation agents with high pressure hot water steam.

Use de-greasers if required.

NOTE: Carry out the dewaxing (deconservation) (see Page 4-1) and washing of the Machine (see Page 7-77) at places equipped with collector bins to collect contaminated water.

7-79

7 - MAINTENANCE

7-80

8 - SPECIFICATIONS

8 - SPECIFICATIONS###_9_### General specification – DV209C and DV209C HF 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

DV209 DV209 HF 9540 kg (21032 lb) 4860 kg (10714 lb) 4860 kg (10714 lb) 500 kg (1100 lb) 10040 kg (22134 lb) 10970 kg (24185 lb) 13000 kg (28660 lb) 28.9 kg/cm – 161.8 lb/in 27.8 kg/cm – 155.7 lb/in 440 kg (970 lb) 150 kg (330 lb) 300 kg (660 lb) 630 kg (1390 lb)

Driving characteristics Maximum transport speed Climbing ability without vibration Climbing ability with vibration Theoretical climbing ability of machine 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

DV209 DV209 HF 11 km/h (6.8 mph) 30% 25% 38% 15% 5470 mm (215.4 in) 7450 mm (293.3 in) Hydrostatic 2 ±6° ±31°

Steering

DV209

Type of steering Steering control Linear hydraulic motors

DV209 HF Joint Hydraulic 1 + 1 (Crab)

Engine Manufacturer Type Power according to ISO 14396 Number of cylinders Cylinder capacity Nominal speed Maximum torque Engines complies with emission regulations Cooling system of engine

DV209

DV209 HF Deutz TCD3.6 L4 74.4 kW (100 Hp) 4 3621 cm³ (221 in³) 2200 RPM 410 N·m at 1600 RPM EU Stage IIIB, U.S. EPA Tier 4 Interim Liquid

Brakes

DV209

DV209 HF Hydrostatic Mechanical multiple-disc Mechanical multiple-disc

Operating Parking Emergency

8-1

8 - SPECIFICATIONS

Vibration

DV209 DV209 HF 42 Hz 46 Hz (2520 Vib/Min) (2760 Vib/Min) 55 Hz 67 Hz (3300 Vib/Min) (4020 Vib/Min) 0.7 mm (0.028 in) 0.62 mm (0.024 in) 0.34 mm (0.013 in) 0.23 mm (0.009 in) 84 kN (18884 lb) 97 kN (21806 lb) 70 kN (15737 lb) Hydrostatic

Frequency I Frequency II Amplitude I Amplitude II Centrifugal force I Centrifugal force II Type of drive Watering

DV209

Type of watering Number of pumps Number of filtrations

DV209 HF Pressure 2 3

Fluid capacities

DV209 DV209 HF 210 L (55.5 US gal) 840 L (221.9 US gal) 9 L (2.4 US gal) 23 L (6.1 US gal) 60 L (15.9 US gal) 10.5 L (2.8 US gal) 10.5 L (2.8 US gal) 2x90 L (2x23.78 US gal) 2x2 L (2x0.53 US gal)

Fuel Water for drum watering Engine (oil filling) Cooling system Hydraulic system Vibrating drum front Vibrating drum rear Drum cooling liquid Drum drive reducer Wiring

DV209

Voltage Battery capacity

DV209 HF 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

DV209

DV209 HF 82 dB 107 dB

<0.5 m/s² (<1.6 ft/s²) <2.5 m/s² (<8.2 ft/s²)

8 - SPECIFICATIONS

General specification – DV210C and DV210C HF 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

DV210 DV210 HF 10310 kg (22730 lb) 5160 kg (11380 lb) 5150 kg (11350 lb) 500 kg (1100 lb) 10810 kg (23830 lb) 11740 kg (25880 lb) 13000 kg (28660 lb) 30.7 kg/cm – 171.9 lb/in 30.7 kg/cm – 171.9 lb/in 440 kg (970 lb) 150 kg (330 lb) 300 kg (660 lb) 630 kg (1390 lb)

Driving characteristics Maximum transport speed Climbing ability without vibration Climbing ability with vibration Theoretical climbing ability of machine 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

DV210 DV210 HF 11 km/h (6.8 mph) 30% 25% 40% 15% 5470 mm (215.4 in) 7450 mm (293.3 in) Hydrostatic 2 ±6° ±31°

Steering

DV210

Type of steering Steering control Linear hydraulic motors

DV210 HF Joint Hydraulic 1 + 1 (Crab)

Engine Manufacturer Type Power according to ISO 14396 Number of cylinders Cylinder capacity Nominal speed Maximum torque Engines complies with emission regulations Cooling system of engine

DV210

DV210 HF Deutz TCD3.6 L4 74.4 kW (100 Hp) 4 3622 cm³ (221 in³) 2200 RPM 410 N·m at 1600 RPM EU Stage IIIB, U.S. EPA Tier 4 Interim Liquid

Brakes

DV210

DV210 HF Hydrostatic Mechanical multiple-disc Mechanical multiple-disc

Operating Parking Emergency

8-3

8 - SPECIFICATIONS

Vibration

DV210 DV210 HF 42 Hz 46 Hz (2520 Vib/Min) (2760 Vib/Min) 52 Hz 67 Hz (3120 Vib/Min) (4020 Vib/Min) 0.82 mm (0.032 in) 0.6 mm (0.024 in) 0.35 mm (0.014 in) 0.22 mm (0.009 in) 120 kN (26977 lb) 105 kN (23605 lb) 78 kN (17535 lb) 82 kN (18434 lb) Hydrostatic Hydrostatic

Frequency I Frequency II Amplitude I Amplitude II Centrifugal force I Centrifugal force II Type of drive Watering

DV210

Type of watering Number of pumps Number of filtrations

DV210 HF Pressure 2 3

Fluid capacities

DV210 DV210 HF 210 L (55.5 US gal) 840 L (221.9 US gal) 9 L (2.4 US gal) 23 L (6.1 US gal) 60 L (15.9 US gal) 10.5 L (2.8 US gal) 10.5 L (2.8 US gal) 2x140 L (2x36.98 US gal) 2x2 L (2x0.53 US gal)

Fuel Water for drum watering Engine (oil filling) Cooling system Hydraulic system Vibrating drum front Vibrating drum rear Drum cooling liquid Drum drive reducer Wiring

DV210

Voltage Battery capacity

DV210 HF 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)

8-4

DV210

DV210 HF 82 dB 107 dB

<0.5 m/s² (<1.6 ft/s²) <2.5 m/s² (<8.2 ft/s²)

8 - SPECIFICATIONS

Dimension

RAIL14COM0307FC

1

DV209C 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)

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 22 mm (0.9 in)

W 1680 mm (66.1 in)

W1 1800 mm (70.9 in)

C 170 mm (6.7 in)

DV210C

8-5

8 - SPECIFICATIONS

RAIL14COM0309HC

8-6

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 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 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).

6. To replace, remove the final compaction disc attachment. The not used cutting disc is to be fixed in the holder.

9-2

RAIL14COM0379FC

3

RAIL14COM0209AA

4

9 - ACCESSORIES

Infrared thermometer The infra thermometer (2) is enabled by turning on the key in the ignition box and it displays the temperature of the rolled bitumen surface using a sensor. The measured temperature is indicated on the display (1) in °C. 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. Holding the OK button for about 4 seconds (or until the audible signal)

RAIL14COM0281AA

1

RAIL14COM0211AA

2

2. When he 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. Using the OK button 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 short pressing the OK button, you can anytime switch over between the upper and lower limit adjustment.

6. By holding the OK button pressed for about 4 seconds (audible signal), you save the set values in the memory.

9-3

9 - ACCESSORIES

Telematics - Overview with Case SiteWatch™ NOTE: The CASE CONSTRUCTION SiteWatch™ website (www.casesitewatch.com) will not be accessible until the CASE CONSTRUCTION SiteWatch™ subscription for this machine is registered by an authorized CASE CONSTRUCTION dealer. Contact an authorized CASE CONSTRUCTION dealer for details.

This machine may be equipped with a Telematics system. This is an asset-monitoring system that combines Internet, cellular, and GPS technologies. A transponder unit is mounted on the equipment that wirelessly communicates with the user interface CASE CONSTRUCTION SiteWatch™ at www.casesitwatch.com. Using cellular technology, the transponder can send equipment data, including location, on/off status, usage and production metrics, diagnostic data, movement alarms, unauthorized usage and monitor machine maintenance to the user interface CASE CONSTRUCTION SiteWatch™. The system will help cut costs and keep accurate records.

9-4

Index ###_Index_###

Air-conditioning compressor drive belt .

Air-conditioning compressor mounting .

Air-conditioning refrigerant level . . .

Air-conditioning system filters . . . .

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

Air filter vacuum valve . . . . . . . .

Assisted starting (Jump-starting) . . .

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A . . . . . . . . . . . . . .

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7-24, 7-61 . . 7-63 . . 7-40 . . 7-41 . . 7-36 . . 7-16 . . 4-6

B Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50 Biodiesel fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 C . . . . . . . .

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D De-conservation and inspection of brand new machines . .

Dimension . . . . . . . . . . . . . . . . . . . . . .

Display screens . . . . . . . . . . . . . . . . . . .

Do Not Operate hang tag . . . . . . . . . . . . . . .

Drain water from the sprinkling circuit before winter season

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. 4-1 . 8-5 . 3-17 . 2-21 . 7-74

E 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 - Check for leaks . . . . . . . . . . . . . . . . . . .

Engine coolant . . . . . . . . . . . . . . . . . . . . . . . .

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

Engine cooling system . . . . . . . . . . . . . . . . . . . .

Engine fuel filter . . . . . . . . . . . . . . . . . . . . . . .

Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil level . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil viscosity — Recommended operating temperature range Exhaust Gas Recirculation (EGR) system . . . . . . . . . . . .

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

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Cab - Control identification .

Cab ventilation air filter . .

Controls and alarms. . . .

Cooling fan . . . . . . .

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3-31 7-73 7-21 7-17

. . 2-26 . . 9-1 . . 1-4 . . 7-59 . . 7-31 . . 7-46 . . 7-60 . . 7-52 . . 7-14 . . 7-68 7-15, 7-37 . . 7-49 . . 7-42 . . 7-32 . . 7-13 . . 7-8 . . 1-11 . . 7-25

F Fluids and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-71 Fuel tank level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18 Gearbox . . . . . . . . . . . . . . . . . . .

Gearbox oil . . . . . . . . . . . . . . . . .

General maintenance safety rules. . . . . . . .

General specification – DV209C and DV209C HF General specification – DV210C and DV210C HF

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G . . . . . . . . . .

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. 7-23 . 7-53 . 2-12 . 8-1 . 8-3

Grease points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28 Hand signals . . . . . . . . . . .

Heating and air-conditioning controls Hydraulic oil and filters . . . . . .

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

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H . . . . . . . .

Ignition lock . . . . .

Infrared thermometer .

Intake manifold - Check Intended use . . . . .

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2-27 3-29 7-64 7-19

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. 3-27 . 9-3 . 7-35 . 1-2

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L Lubrication and service schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M Machine cleaning . . . . . . . . . . . . . . . . . . .

Machine components . . . . . . . . . . . . . . . . .

Machine orientation . . . . . . . . . . . . . . . . . .

Machine parking . . . . . . . . . . . . . . . . . . .

Machine preservation and storage for longer than 2 month .

Machine transport (on a trailer) . . . . . . . . . . . . .

Machine travel and reversing . . . . . . . . . . . . . .

Machine travel and reversing including vibration . . . . .

Maintenance chart . . . . . . . . . . . . . . . . . .

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7-77 1-9 1-8 4-13 7-79 5-2 4-10 6-5 7-11

N Note to the owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

O Operating the machine at high altitudes . . . . . . . . .

Operating the machine at high temperatures and humidity .

Operating the machine at low temperatures . . . . . . .

Operating the machine during running-in period. . . . . .

Operating the machine in extremely dusty environment . .

Operating with vibration on compacted and hard materials .

Operator's Manual storage on the machine. . . . . . . .

Operator seat . . . . . . . . . . . . . . . . . . . .

6-3 6-2 6-1 4-2 6-4 6-8 1-7 3-3

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7-9

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P Personal Protective Equipment (PPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 R Safety rules . . . . . . . . . . . . . . . . . .

Safety rules - Air-conditioning system . . . . . . .

Safety rules and signal word definitions . . . . . .

Safety rules - Basic operating . . . . . . . . . .

Safety rules - Battery . . . . . . . . . . . . . .

Safety rules - California Proposition 65 Warning . .

Safety rules - Electrical storm safety . . . . . . .

Safety rules - Fire or explosion prevention . . . . .

Safety rules - General . . . . . . . . . . . . .

Safety rules - Hazardous chemicals . . . . . . .

Safety rules - Mounting and dismounting . . . . .

Safety rules - Operator presence system . . . . .

Safety rules - Roll Over Protective Structure (ROPS) Safety rules - Seat belt . . . . . . . . . . . . .

Safety rules - Utility precautions . . . . . . . . .

Safety signs . . . . . . . . . . . . . . . . . .

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

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2-3 2-19 2-1 2-10 2-14 2-2 2-24 2-13 2-9 2-22 2-25 2-15 2-17 2-16 2-23 2-30 7-76

Short term storage . . . . . . .

Sprinkling . . . . . . . . . . .

Starting the engine . . . . . . .

Steering column . . . . . . . .

Stopping the machine . . . . . .

Suspension and silencing system .

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Telematics - Overview with Case SiteWatch™ Tightening torques . . . . . . . . . . . .

Towing the machine . . . . . . . . . . . .

Transport mode . . . . . . . . . . . . .

Traveling on public roads . . . . . . . . .

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. 7-78 . 6-7 . 4-3 . 3-5 . 4-8 . 7-55

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. 9-4 . 7-1 . 5-4 . 3-28 . 5-1

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V Vibrations system oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54 Water / Oil / Intercooler Radiator Water filter . . . . . . . . . .

Water Separator . . . . . . .

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

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

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. 7-58, 7-72 . . . . 7-26 . . . . 7-39 . 7-20, 7-57 . . . . 7-38

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.

Copyright © 2014 CNH Industrial America LLC. All Rights Reserved.

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