Case DV209C DV210C Tier 4A Vibratory Roller Service Manual 47772910 - PDF DOWNLOAD

DV209C DV210C Tier 4A Vibratory Roller

SERVICE MANUAL

Printed in U.S.A. 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.

Part number 47772910 1st edition English December 2014

Contents INTRODUCTION Machine completion and equipment .............................................. 05 [05.102] Machine completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05.1

Engine....................................................................................... 10 [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

Hydrostatic drive......................................................................... 29 [29.218] Pump and motor components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.1

Hydraulic systems....................................................................... 35 [35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.752] Hydraulic fan drive cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.353] Hydraulic travel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 [35.995] Compaction/vibration hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5

Frames and ballasting ................................................................. 39 [39.100] Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1 [39.500] Vibratory roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.2

Steering..................................................................................... 41 [41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1 [41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 [41.206] Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3 [41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.4

Wheels ...................................................................................... 44 [44.160] Compaction drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1

Cab climate control ..................................................................... 50 47772910 15/12/2014

[50.100] Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1

Electrical systems ....................................................................... 55 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system. . . . . . . . . . . . . . . . . 55.5 [55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6

Platform, cab, bodywork, and decals ............................................. 90 [90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1

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INTRODUCTION

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Contents INTRODUCTION Foreword - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Safety rules - Ecology and the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Safety rules - Shop and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Safety rules – Hydraulic contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Hydraulic contamination – Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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INTRODUCTION

Foreword - Important notice regarding equipment servicing All repair and maintenance work listed in this manual must be carried out only by qualified dealership personnel, strictly complying with the instructions given, and using, whenever possible, the special tools.

Anyone who performs repair and maintenance operations without complying with the procedures provided herein shall be responsible for any subsequent damages.

The manufacturer and all the organizations of its distribution chain, including - without limitation - national, regional, or local dealers, reject any responsibility for damages caused by parts and/or components not approved by the manufacturer, including those used for the servicing or repair of the product manufactured or marketed by the manufacturer.

In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case of damages caused by parts and/or components not approved by the manufacturer.

The manufacturer 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.

In case of questions, refer to your CASE CONSTRUCTION Sales and Service Networks.

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Safety rules Personal safety This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury.

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

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

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

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

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

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

Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or property damage. The word Notice is used to address practices not related to personal safety.

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

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

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Safety rules Carefully read the safety rules contained herein and follow advised precautions to avoid potential hazards and to safeguard your safety and personal integrity.

Your safety and that of the people around you depends on you.

It is essential that you understand this manual for a correct inspection, lubrication and repair of this machine.

Read this manual carefully and check that: • You understand fully the symbols on the controls and the safety signs used in this manual and on the machine.

• You understand fully the speed, stability, braking and steering characteristics of the machine. If you are in any doubt, consult your Dealer.

The safety messages in this section concern situations which may arise during normal machine operation, servicing and repair. These safety messages also indicate the different ways of coping with these situations. Other safety messages are used throughout the manual to indicate specific dangers.

The information given in this chapter is a summary of the basic rules to respect at all times and does not exempt you from observing traffic regulations or the requirements of insurance companies.

The presence of grease, oil, mud or (in winter) ice on the steps and access handles can cause accidents. Make sure they are always clean.

When mounting or dismounting from the machine always face the machine and use the steps and access handles on the left-hand side of the machine.

LELI12TLB0048AB

1

LELI12TLB0049AB

2

Wear close fitting clothing and safety equipment appropriate for the job: • Safety helmet • Safety shoes • Heavy gloves • Reflective clothing • Wet weather clothing If the environment conditions make it necessary, the following personal safety equipment should be at hand: • Respirators (or dustproof masks) • Ear plugs or acoustic ears protections • Goggles with lateral shield or masks for eyes protection Do not wear rings, wristwatches, jewels, unbuttoned or flapping clothing such as ties, torn clothes, scarves, open jackets or shirts with open zips which could get caught into moving parts.

Any functional disorders, especially those affecting the safety of the machine, should therefore be rectified immediately.

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Make sure that you fully understand the symbols of the safety decals applied on the machine. Make sure that they are always clean and perfectly legible.

Be prepared for emergencies.

Always keep a first aid kit and a fire extinguisher close at hand on the machine.

Make sure that the fire extinguisher is serviced in accordance with the manufacturer’s instructions.

LELI12TLB0050AB

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Safety rules Prevention of fire or explosions The engine fuel can originate an explosion or a fire.

Never refuel when the engine is running.

Do not smoke during refuelling.

Take all the necessary safety measures when welding, grinding or when working near a naked flame.

Use a non-inflammable product for cleaning parts.

LELI12TLB0051AA

1

LELI12TLB0052AA

2

A spark or a flame can cause the electrolyte of the battery to explode.

To prevent any risk of explosion, observe the following instructions: • When disconnecting the battery cables, always disconnect the negative (-) cable first.

• To reconnect the battery cables, always connect the negative (-) cable last.

• Never short-circuit the battery clamps with metal objects.

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

The engine exhaust may produce sparks.

Before using the machine in an area which may contain inflammable vapours, ensure that there is good ventilation.

Always keep a fire extinguisher available on the machine.

Make sure that it is properly maintained in conformity with the manufacturer’s instructions.

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Prevention of burns The battery electrolyte generates severe burns.

The battery contains sulphuric acid.

Avoid any contact with the skin, eyes or clothing.

Antidote: • EXTERNAL: Rinse well with water, removing any soiled clothing.

• INTERNAL: Avoid vomiting. Drink water to rinse your mouth. Consult a doctor.

• EYES: Rinse thoroughly with water for 15 min and get prompt medical attention.

LELI12TLB0053AA

3

LELI12TLB0054AA

4

LELI12TLB0055AA

5

When the electrolyte of a battery is frozen, it can explode if you attempt to charge the battery or if you try to start the engine using a booster battery.

Always keep the battery charged to prevent the electrolyte freezing.

Batteries generate explosive gases.

Keep all flames, sparks and cigarettes away.

Provide good ventilation when changing a battery or using a battery in an enclosed space.

Always protect your eyes when working near a battery.

Never touch the battery terminals with your hands.

This can induce a state of electrolysis and impair the main organs of the body.

Hot coolant could spray out if the radiator cap is removed while the system is still hot.

To remove the cap: Allow the system to cool down, turn the cap to the first notch and wait until there is no more pressure.

Then remove the cap.

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Precautions for waste disposal Improperly disposing of waste can threaten the environment.

Each country has its own Regulations on this subject. It is therefore advisable to prepare suitable containers to collect and store momentarily all solid and fluid materials that must not be scattered in the environment to avoid pollution.

At preset intervals these products will be delivered to disposal stations legally recognized and present in this Country.

Here below is a list of the products in the machine which require disposal:

LELI12TLB0056AA

• Hydraulic oil • Brake system oil • Coolant mixture, condensation residue and pure antifreeze • Diesel oil • Oil and diesel oil filter elements • Engine and air-conditioning air filter elements • Battery Also polluting rags, paper, sawdust and gloves must be disposed in compliance with the same procedures.

Do not use food or beverage containers that may mislead someone into drinking from them.

Do not pour waste onto the ground, down a drain, or into any water source.

Air-conditioning coolant escaping into the air can damage the Earth’s atmosphere.

Government regulations may require a certified air-conditioning service centre to recover and recycle used air-conditioning coolant.

Obtain information on the proper way to recycle or dispose of waste from your local environmental or recycling centre, or from your Dealer.

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

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

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

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

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

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

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

• The air-conditioning system contains gases that should not be released into the atmosphere. Consult an air-conditioning specialist or use a special extractor to recharge the system properly.

• Repair any leaks or defects in the engine cooling system 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. Penetrating weld splatter may burn a hole or weaken hoses, allowing the loss of oils, coolant, etc.

Battery recycling Batteries and electric accumulators contain several substances that can have a harmful effect on the environment if the batteries are not properly recycled after use. Improper disposal of batteries can contaminate the soil, groundwater, and waterways. CASE CONSTRUCTION strongly recommends that you return all used batteries to a CASE CONSTRUCTION dealer, who will dispose of the used batteries or recycle the used batteries properly. In some countries, this is a legal requirement.

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

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

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

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Safety rules - Shop and assembly O-ring seals Lubricate the O-ring seals before you insert them in the seats. This will prevent the O-ring seals from overturning and twisting, which would jeopardize sealing efficiency.

Sealing compounds Apply a sealing compound on the mating surfaces when specified by the procedure. Before you apply the sealing compound, prepare the surfaces as directed by the product container.

Spare parts Only use CNH Original Parts.

Only genuine spare parts guarantee the same quality, duration, and safety as original parts, as they are the same parts that are assembled during standard production. Only CNH Original Parts can offer this guarantee.

When ordering spare parts, always provide the following information: • Machine model (commercial name) and Product Identification Number (PIN) • Part number of the ordered part, which can be found in the parts catalog

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Protecting the electronic and/or electrical systems during charging and welding To avoid damage to the electronic and/or electrical systems, always observe the following practices: 1. Never make or break any of the charging circuit connections when the engine is running, including the battery connections.

2. Never short any of the charging components to ground.

3. Always disconnect the ground cable from the battery before arc welding on the machine or on any machine attachment.

• Position the welder ground clamp as close to the welding area as possible.

• If you weld in close proximity to a computer module, then you should remove the module from the machine.

• Never allow welding cables to lie on, near, or across any electrical wiring or electronic component while you weld.

4. Always disconnect the negative cable from the battery when charging the battery in the machine with a battery charger.

NOTICE: If you must weld on the unit, you must disconnect the battery ground cable from the machine battery.

The electronic monitoring system and charging system will be damaged if this is not done.

5. Remove the battery ground cable. Reconnect the cable when you complete welding.

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

Special tools The special tools that CASE CONSTRUCTION suggests and illustrate in this manual have been specifically researched and designed for use with CASE CONSTRUCTION machines. The special tools are essential for reliable repair operations. The special tools are accurately built and rigorously tested to offer efficient and long-lasting operation.

By using these tools, repair personnel will benefit from: • Operating in optimal technical conditions • Obtaining the best results • Saving time and effort • Working in safe conditions

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Safety rules – Hydraulic contamination Contamination in the hydraulic system is a major cause of the malfunction of hydraulic components. Contamination is any foreign material in the hydraulic oil.

Contamination can enter the hydraulic system in several ways: • When you drain the oil or disconnect any line • When you disassemble a component • From normal wear of the hydraulic components • From damaged seals or worn seals • From a damaged component in the hydraulic system All hydraulic systems operate with some contamination. The design of the components in this hydraulic system permits efficient operation with a small amount of contamination. An increase in this amount of contamination can cause problems in the hydraulic system.

The following list includes some of these problems: • Cylinder rod seals that leak • Hydraulic oil that becomes too hot • Pump gears, housing, and other parts that wear rapidly • Relief valves or check valves held open by dirt • Quick failure of components that have been repaired • The machine does not have enough power.

If your machine has any of these problems, check the hydraulic oil for contamination.

There are two types of contamination: microscopic and visible.

Microscopic contamination occurs when very fine particles of foreign material are suspended in the hydraulic oil.

These particles are too small to see or feel. Microscopic contamination can be found by identification of the following problems or by testing in a laboratory.

Examples of problems caused by microscopic contamination: • Cylinder rod seals that leak • The hydraulic system has a high operating temperature Visible contamination is foreign material that can be found by sight, touch, or odor. Visible contamination can cause a sudden failure of components.

Examples of problems caused by visible contamination: • Particles of metal or dirt in the oil • Air in the oil • Dark or thick oil • Oil with an odor of burned oil • Water in the oil If you find contamination, use a portable filter to clean the hydraulic system.

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

Wear working footwear with non-slip soles. Smooth soles may slip from steps and pedals resulting in injury or incorrect operation.

Wear closely fitting work clothes when operating the machine. Loose, wide garments may result in the control lever being inadvertently activated.

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

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

Always wear eye protection when working with batteries.

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

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.

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

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

• If hydraulic fluid or diesel 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.

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Torque • Confirm regularly that bolted connections have not come loose.

• Use torque wrenches for tightening.

• If a special torque is needed, it is mentioned in the section.

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

TIGHTENING TORQUE For screws 8.8 (8G) 10 N·m (7.4 lb ft) 24 N·m (17.7 lb ft) 19 N·m (14.0 lb ft) 48 N·m (35.4 lb ft) 38 N·m (28.0 lb ft) 83 N·m (61.2 lb ft) 66 N·m (48.7 lb ft) 132 N·m (97.4 lb ft) 106 N·m (78.2 lb ft) 200 N·m (147.5 lb ft) 160 N·m (118.0 lb ft) 275 N·m (202.8 lb ft) 220 N·m (162.3 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 (313.5 lb ft) 675 N·m (497.9 lb ft) 540 N·m (398.3 lb ft) 995 N·m (733.9 lb ft) 795 N·m (586.4 lb ft) 1350 N·m (995.7 lb ft) 1080 N·m (796.6 lb ft)

For srews 10.9 (10K) 14 N·m (10.3 lb ft) 34 N·m (25.1 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 (86.3 lb ft) 94 N·m (69.3 lb ft) 185 N·m (136.4 lb ft) 148 N·m (109.2 lb ft) 285 N·m (210.2 lb ft) 228 N·m (168.2 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 (549.5 lb ft) 590 N·m (435.2 lb ft) 950 N·m (700.7 lb ft) 760 N·m (560.5 lb ft) 1400 N·m (1032.6 lb ft) 1120 N·m (826.0 lb ft) 1900 N·m (1401.4 lb ft) 1520 N·m (1121.1 lb ft)

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

Table with torques of cap nuts with O-ring - hoses Size wrench

Thread size

Hose

14

12x1.5

6

17

14x1.5

8

19

16x1.5

22

18x1.5

24

20x1.5

12

27

22x1.5

14 15

30

24x1.5

16

32

26x1.5

18

8 10 10 12

Tightening torques for cap nuts with O-ring - hoses Nominal Min Max 20 N·m (14.8 lb 15 N·m (11.1 lb 25 N·m (18.4 lb ft) ft) ft) 38 N·m (28.0 lb 30 N·m (22.1 lb 45 N·m (33.2 lb ft) ft) ft) 45 N·m (33.2 lb 38 N·m (28.0 lb 52 N·m (38.4 lb ft) ft) ft) 51 N·m (37.6 lb 43 N·m (31.7 lb 58 N·m (42.8 lb ft) ft) ft) 58 N·m (42.8 lb 50 N·m (36.9 lb 65 N·m (47.9 lb ft) ft) ft) 74 N·m (54.6 lb 60 N·m (44.3 lb 88 N·m (64.9 lb ft) ft) ft) 74 N·m (54.6 lb 60 N·m (44.3 lb 88 N·m (64.9 lb ft) ft) ft) 105 N·m (77.4 lb 85 N·m (62.7 lb 125 N·m (92.2 lb ft) ft) ft)

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INTRODUCTION

Size wrench

Thread size

36

30x2

41 46

36x2

50

42x2

30

45x2

35

52x2

38 42

50

Tightening torques for cap nuts with O-ring - hoses Nominal Min Max 135 N·m (99.6 lb 115 N·m (84.8 lb 155 N·m (114.3 lb ft) ft) ft) 166 N·m (122.4 lb 140 N·m (103.3 lb 192 N·m (141.6 lb ft) ft) ft) 240 N·m (177.0 lb 210 N·m (154.9 lb 270 N·m (199.1 lb ft) ft) ft) 290 N·m (213.9 lb 255 N·m (188.1 lb 325 N·m (239.7 lb ft) ft) ft) 330 N·m (243.4 lb 280 N·m (206.5 lb 380 N·m (280.3 lb ft) ft) ft)

Hose 20 22 25 28

Table for torques of necks with sealing edge or with flat gasket G-M G 1/8 G1/4 G 3/8 G 1/2 G 3/4 G1 G 11/4 G 11/2

Tightening torques for flanges 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)

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 x 1.5 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)

SS12C493

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1

INTRODUCTION

Table for torques of plugs with flat gasket G-M G 1/8 G1/4 G 3/8 G 1/2 G 3/4 G1 G 11/4 G 11/2

Tightening torques for flanges 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 x 1.5 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)

SS12K194

2

SS12N446

3

Hydraulic cylinder for steering 80/45–320 (2) Piston rod, (3) Piston, (4) Nut Thread M30x2

Tightening torque 130 N·m (96 lb ft)

(1) Hydraulic cylinder body, (5) Hydraulic cylinder cover Thread Tightening torque M85x1.5 180 N·m (133 lb ft)

Hydraulic cylinder for CRAB 110/55–125 (2) Piston rod, (3) Piston, (4) Nut Thread M42x3

Tightening torque 180 N·m (133 lb ft)

(1) Hydraulic cylinder body, (5) Hydraulic cylinder cover Thread Tightening torque M115x2 220 N·m (162 lb ft)

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INTRODUCTION

Hydraulic contamination – Contamination Contamination in the hydraulic system is a major cause of the malfunction of hydraulic components. Contamination is any foreign material in the hydraulic oil. Contamination can enter the hydraulic system in several ways.

1. When you drain the oil or disconnect any line.

2. When you disassemble a component.

3. From normal wear of the hydraulic components.

4. From damaged or worn seals.

5. From a damaged component in the hydraulic system.

All hydraulic systems operate with some contamination. The design of the components in this hydraulic system permits efficient operation with a small amount of contamination. An increase in this amount of contamination can cause problems in the hydraulic system. The following list includes some of these problems.

1. Cylinder rod seals leak.

2. Control valve spools do not return to neutral.

3. Movement of control valve spools is difficult.

4. Hydraulic oil becomes too hot.

5. Pump gears, housing, and other parts wear rapidly.

6. Relief valves or check valves held open by dirt.

7. Quick failure of components that have been repaired.

8. Cycle times are slow; machine does not have enough power.

If your machine has any of these problems, check the hydraulic oil for contamination. See types of contamination below. If you find contamination, use the Portable Filter to clean the hydraulic system.

NOTE: There are two types of contamination, microscopic and visible.

Microscopic contamination occurs when very fine particles of foreign material are in suspension in the hydraulic oil.

These particles are too small to see or feel. Microscopic contamination can be found by identification of the following problems or by testing in a laboratory. Examples of the problems: 1. Cylinder rod seal leak.

2. Control valve spools do not return to NEUTRAL. 3. The hydraulic system has a high operating temperature.

Visible contamination is foreign material that can be found by sight, touch, or odor. Visible contamination can cause a sudden failure of components. Examples of visible contamination: 1. Particles of metal or dirt in the oil.

2. Air in the oil.

3. The oil is dark and thick.

4. The oil has an odor of burned oil.

5. Water in the oil.

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INTRODUCTION

Consumables 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

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0.3 L (0.08 US gal)

INTRODUCTION

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

Performance classification under: American Petroleum Institute (API)

Viscosity classification The ambient temperature and type of operations at the place where the machine will be used are decisive in determining Society of Automotive Engineers (SAE) viscosity class.

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

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

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

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

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

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INTRODUCTION

NOTICE: Do not allow the upper temperature limit to be exceeded for long periods of time as this will reduce the capabilities of the oil.

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

Viscosity diagram

SS12C358

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1

INTRODUCTION

Fuel

WARNING Fire hazard!

Do not add gasoline, alcohol, or blended fuels to diesel fuel, except as recommended in this manual.

Fuel combinations may increase fire and explosion hazards.

Failure to comply could result in death or serious injury.

W0401A

Use fuel that complies with the American Society for Testing and Materials (ASTM) D975 standard: Grade no. 2 fuel Fuel viscosity must be over 1.3 centi Stokes (cSt) at 40 °C (104 °F) to ensure proper liquidity characteristics and proper lubrication of fuel system components.

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

Coolant

WARNING Chemical hazard!

Follow the instructions on the container when handling anti-freeze.

Failure to comply could result in death or serious injury.

W1109A

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

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

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

NOTICE: Do not use coolant with an antifreeze concentration greater than 50 %. Point of congelation is -36 °C (-33 °F) and the boiling point is 110 °C (230 °F), unless absolutely required.

Never use an antifreeze concentration over 68 %!

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

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

Hydraulic oil Only hydraulic oil CASE AKCELA HY-TRAN® ULTRA™ HYDRAULIC TRANSMISSION OIL may be used for the machine’s hydraulic system.

Fill the machine with hydraulic oil of cinematic viscosity 68 mm² per second at 40 °C (104 °F), i.e. ISO VG 68. This oil is most appropriate for use within the widest range of ambient temperatures.

Synthetic hydraulic oil It is possible to fill the hydraulic system with synthetic oil for which any leakage will be completely biodegraded via microorganisms found in water and soil.

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

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INTRODUCTION

Transmission fluid Use high-quality oil corresponding to API GL-5, or EP or MIL-L-2105 D to lubricate gearbox, pumps and drum reductors.

Use TUTELA HYPOIDE SSL SYNTHETIC GEAR LUBE SAE 75W-90 fluid for outdoor temperature range -10 - 30 °C (14 86 °F). or use TUTELA HYPOIDE SSL SYNTHETIC GEAR LUBE SAE 80W-140 fluid for outdoor temperature range 20 - 45 °C (68 - 113 °F).

NOTICE: Operating temperature of oil should never exceed 85 - 90 °C (185 - 194 °F).

Brake fluid The fluid should comply with international specifications DOT3. It is mixable with brake fluids of all brands that comply with these specifications. Brake fluid is designed for brake systems that operate at ambient temperatures from -50 °C (-58 °F) to 60 °C (140 °F) and at operating temperatures from -50 °C (-58 °F) to 205 °C (401 °F).

NOTICE: Brake fluid that corresponds to the international classification DOT 4 may also be used for the brake system.

Lube grease Use plastic lubricant with lithium content to lubricate the machine: Case Akcela Extreme pressure grease moly To lubricate the speed reduction transmission, use the lubricant according to: ISO 6743/9 BDHB2

Washer fluid Use clean water at a temperature of no lower than 0 °C (32 °F) when filling the washer fluid reservoir. We recommend the use of washer fluid with antifreeze for motor vehicle windshield washers at the ratio necessitated by machine lubricating conditions.

NOTICE: When there is a risk that temperatures will drop below 0 °C (32 °F), add antifreeze agent or drain the water!

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

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INTRODUCTION

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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INTRODUCTION

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

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INTRODUCTION

Product identification

RAIL14COM0271HC

1

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INTRODUCTION

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.

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

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INTRODUCTION

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SERVICE MANUAL Machine completion and equipment DV209C DV210C

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Contents Machine completion and equipment - 05

[05.102] Machine completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05.1

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Machine completion and equipment - 05 Machine completion - 102

DV209C DV210C

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Contents Machine completion and equipment - 05 Machine completion - 102

TECHNICAL DATA Machine completion General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

(*) See content for specific models 47772910 15/12/2014

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Machine completion and equipment - Machine completion

Machine completion - General specification DV209C

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 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 HF Joint Hydraulic 1 + 1 (Crab)

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

Vibration

DV209 42 Hz (2520 Vib/Min) 55 Hz (3300 Vib/Min)

Operating Parking Emergency

Frequency I Frequency II 47772910 15/12/2014

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DV209 HF 46 Hz (2760 Vib/Min) 67 Hz (4020 Vib/Min)

Machine completion and equipment - Machine completion

Vibration

DV209 DV209 HF 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

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)

DV209

DV209 HF 82 dB 107 dB

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

Machine completion - General specification DV210C

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

DV210 DV210 HF 11 km/h (6.8 mph) 30% 25%

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Machine completion and equipment - Machine completion

Driving characteristics 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 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 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 HF Joint Hydraulic 1 + 1 (Crab)

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 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 47772910 15/12/2014

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Machine completion and equipment - Machine completion

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)

DV210

DV210 HF 82 dB 107 dB

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

Machine completion - Dimension DV209C

RAIL14COM0307FC

1

A 3500 mm (137.8 in)

D 1220 mm (48 in)

H 3000 mm (118.1 in)

G1 780 mm (30.7 in)

G 300 mm (11.8 in)

L 4720 mm (185.8 in)

T 19 mm (0.7 in)

W 1680 mm (66.1 in)

W1 1800 mm (70.9 in)

C 170 mm (6.7 in)

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Machine completion and equipment - Machine completion

RAIL14COM0309HC

2

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Machine completion and equipment - Machine completion

Machine completion - Dimension DV210C

RAIL14COM0307FC

1

A 3500 mm (137.8 in)

D 1220 mm (48 in)

H 3000 mm (118.1 in)

G1 780 mm (30.7 in)

G 300 mm (11.8 in)

L 4720 mm (185.8 in)

T 22 mm (0.9 in)

W 1680 mm (66.1 in)

W1 1800 mm (70.9 in)

C 170 mm (6.7 in)

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Machine completion and equipment - Machine completion

RAIL14COM0309HC

2

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Index Machine completion and equipment - 05 Machine completion - 102 Machine completion - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Machine completion - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Machine completion - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Machine completion - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

(*) See content for specific models 47772910 15/12/2014

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 2014 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

CASE CONSTRUCTION policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved.

All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your CASE CONSTRUCTION Dealer.

47772910 15/12/2014 EN

SERVICE MANUAL Engine DV209C DV210C

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Contents Engine - 10

[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

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10

Engine - 10 Engine and crankcase - 001

DV209C DV210C

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Contents Engine - 10 Engine and crankcase - 001

TECHNICAL DATA Engine General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Engine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

SERVICE Engine Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

DIAGNOSTIC Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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Engine - Engine and crankcase

Engine - General specification Engine type TCD 3.6 L4 Working principle Four-stroke diesel engine Turbocharger with charge air cooling Charging Type of cooling water-cooled Cylinder arrangement in series No. of cylinders 4 98 mm (3.86 in) / 120 mm (4.72 in) Bore/stroke Total displacement 3621 cm³ (221 in³) Direct injection Combustion process Injection system Common Rail Exhaust gas recirculation externally cooled Exhaust gas aftertreatment Diesel oxidation catalytic converter DOC Valves per cylinder 2 Firing order of the engine 1-3-4-2 Direction of rotation looking onto the flywheel left Engine power rating according to ISO 3046 See engine rating plate Speed (nominal revolutions) See engine rating plate Injection timing See engine rating plate 4.6 L (1.22 US gal) Coolant volume Permissible continuous coolant temperature max. 110 °C (230 °F) 8 °C (15 °F) Temperature difference between coolant inlet/outlet Start of thermostat opening 88 °C (190 °F) Thermostat fully open 95 °C (203 °F) Lubricating oil change volume (with filter) 8 L (2.1 US gal) Lube oil temperature in the lube oil tray, maximum 125 °C (257 °F) Lubricating oil pressure minimum (low idle, engine warm) 80 kPa (11.6 psi) Permissible maximum combustion air temperature after charge air cooler 50 °C (122 °F) Pre-tensioning: 600 - 700 N (134.9 157.4 lb) V-belt tension: V-belts AVX (width: 13 mm) Re-tensioning: 350 - 450 N (78.7 101.2 lb) Automatic tensioning spring-loaded V-rib belt tensioning clamping roller Weight without cooling system according to DIN 70020-A 350 kg (772 lb)

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Engine - Engine and crankcase

Engine - Overview

RAIL14COM0799HA

1

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Engine - Engine and crankcase

S. No 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

Description Clamp Bolt Washer Lock washer Nut Indicator Air filter Hose clamp Reducer Duct Duct Pipe Engine Clamp Gasket Duct Compensator Catalytic converter

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Engine - Engine and crankcase

RAIL14COM0800GA

S. No 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

2

Description Engine Claw Rubber mount Hexagonal screw Socket head cap screw Lock washer Washer Nut Engine control unit Holder

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Engine - Engine and crankcase

RAIL14COM0801HA

S. No 1.

2.

3

Description Engine Radiator 47772910 15/12/2014

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Engine - Engine and crankcase

S. No 3.

4.

5.

6.

7.

Description Clamp Air duct Coupling Coolant tube Elbow

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Engine - Engine and crankcase

RAIL14COM0802HA

S. No 1.

2.

4

Description Fan Bracket 47772910 15/12/2014

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Engine - Engine and crankcase

S. No 3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

Description Plate Hydraulic motor Radiator cover Bolt Washer Lock washer Vibration isolator Bracket Radiator Steering pump Cooling pump

RAIL14COM0803GA

S. No 1.

2.

3.

5

Description Engine Clamp Hose 47772910 15/12/2014

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Engine - Engine and crankcase

S. No 4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

Description Hose Fitting Sealing ring Filter Filter Bolt Spring washer Fuel pump Nut Cap screw Holder Pressure sensor Hose Hose

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Engine - Engine and crankcase

Engine - Component identification Engine name plate (1)

RAIL14COM0213AA

1

RAIL14COM0408AA

2

RAIL14COM0409AA

3

View from right 1.

Crankcase breather

2.

Throttle valve

3.

Tension pulley

4.

V-rib belt

5.

Coolant inlet

6.

Lubricating oil drain plug

7.

Lube oil replacement filter

8.

Lubricating oil dipstick

9.

Coolant outlet

View from left 1. Combustion air inlet 2. Exhaust outlet 3. Diesel particle filter 4. Diesel oxidation catalytic converter 5. Lubricating oil dipstick - Optional 6. Lube oil replacement filter - Optional 7. Lubricating oil filling

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Engine - Engine and crankcase

Electronic engine control 1.

Rail pressure sensor

2.

Charge air pressure transmitter, charge air temperature transmitter

3.

Coolant temperature transmitter

4.

Engine control unit

5.

Speed transmitter via camshaft

6.

Speed transmitter via crankshaft

7.

Fuel transducer

8.

Lubricating oil pressure transmitter (on the opposite side)

9.

Central plug (for engine control)

RAIL14COM0410AA

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4

Engine - Engine and crankcase

Engine - Remove 1. Remove the cab (refer to Cab - Remove (90.150)).

2. Remove the platform (refer to Cab and platform - Remove (90.150)).

3. Remove the vibration pump for the front drum (refer to Pump - Remove the pump for front drum vibrations (29.218) ).

4. Remove the vibration pump for the rear drum (refer to Pump - Remove the pump for rear drum vibrations (29.218) ).

5. Remove the travel pump (refer to Pump - Remove the travel pump (29.218) ).

6. Place a suitable drain collector with adequate capacity under the frame to collect the drain oil.

NOTE: Approximate drain volume: 9 L (2.4 US gal).

7. Remove the drain plugs and drain the engine oil.

RAIL14COM0411AA

1

RAIL14COM0412AA

2

RAIL14COM0413AA

3

8. Remove the tie wraps as required.

9. Remove the Engine Control Unit (ECU) (1).

10. Remove the ECU bracket (2).

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Engine - Engine and crankcase

11. Remove the bracket (3) and attaching hardware.

12. Disconnect the connectors (4) from the bracket (3).

RAIL14COM0414AA

4

RAIL14COM0415AA

5

RAIL14COM0416AA

6

13. Disconnect the connectors (4) from the ECU (1).

14. Plug the connectors with protective caps and store the ECU appropriately.

15. Remove the clamps (5) and (6).

16. Remove the ducts (7), (8) and (9) and clamps (5) from the intercooler (10).

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Engine - Engine and crankcase

17. Remove the clamps (5) and (11).

18. Remove the clamp (15) and attaching hardware.

19. Remove the ducts (12), (13) and (14) and clamps (23) from the intercooler (10).

RAIL14COM0417AA

7

RAIL14COM0418AA

8

RAIL14COM0419AA

9

20. Remove the clamp (16).

21. Disconnect the duct (17) from the turbocharger.

22. Remove the clamps (18).

23. Remove the duct (19) and gaskets (20).

RAIL14COM0420AA

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10

Engine - Engine and crankcase

24. Close the fuel shut-off valves (21).

RAIL14COM0421AA

11

RAIL14COM0422AA

12

RAIL14COM0423AA

13

RAIL14COM0424AA

14

25. Disconnect the connector (X12) from the fuel pump.

26. Disconnect the connector (A) from the fuel pressure sensor.

27. Disconnect the connector from the Water in fuel switch (S38).

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Engine - Engine and crankcase

28. Remove the hoses (22) and (23) from the filter assemblies.

RAIL14COM0425AA

15

RAIL14COM0426AA

16

RAIL14COM0427AA

17

RAIL14COM0428AA

18

29. Remove the attaching hardware (28) and bracket (24) with the filter assemblies.

30. Disconnect the connector from the coolant level sensor (S36).

31. Disconnect the hoses (27) and (28) from the expansion tank (26).

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Engine - Engine and crankcase

32. Remove the clamps and disconnect the hose (29) from the coolant pump.

RAIL14COM0429AA

19

RAIL14COM0430AA

20

RAIL14COM0431AA

21

RAIL14COM0432AA

22

33. Remove the attaching hardware and bracket (30) with the differential lock valve (31).

34. Move the bracket assembly (30) out of the work area and secure it with a tie-wrap.

35. Disconnect the D+ terminal from the alternator.

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Engine - Engine and crankcase

36. Disconnect the hoses (32) and (33) from the steering pump.

RAIL14COM0433AA

23

RAIL14COM0434AA

24

RAIL14COM0435AA

25

RAIL14COM0436AA

26

37. Disconnect the hose (34) from the cooling pump.

38. Disconnect the terminals from the fuses.

39. Disconnect the connector (X50).

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40. Remove the clamp (35).

41. Remove the hose (36).

RAIL14COM0437AA

27

RAIL14COM0438AA

28

RAIL14COM0439AA

29

RAIL14COM0440AA

30

42. Remove the engine oil drain hose (37) from the fitting.

43. Remove the clamps (35) and hose (38).

44. Disconnect the engine connector (X6).

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Engine - Engine and crankcase

45. Disconnect the wires from the starter.

RAIL14COM0441AA

31

RAIL14COM0442AA

32

RAIL14COM0443AA

33

RAIL14COM0444AA

34

46. Disconnect the engine ground terminal.

47. Remove the bolts (40) and washers (41).

48. Remove the engine mounts (39).

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Engine - Engine and crankcase

49. Install the lifting lugs on the engine as shown.

50. Install the hoisting chains on the lifting lugs.

RAIL14COM0446AA

35

RAIL14COM0447AA

36

RAIL14COM0448AA

37

51. Lift and remove the engine from the engine compartment with a lifting device of adequate capacity.

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Engine - Engine and crankcase

Engine - Install 1. Install the lifting lugs on the engine as shown.

2. Install the hoisting chains on the lifting lugs.

RAIL14COM0446AA

1

RAIL14COM0447AA

2

RAIL14COM0448AA

3

3. Lift the engine with a lifting device of adequate capacity.

Place the engine in its correct position in the engine compartment.

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Engine - Engine and crankcase

4. Install the engine mounts (39) with the bolts (40) and washers (41).

RAIL14COM0443AA

4

RAIL14COM0444AA

5

RAIL14COM0442AA

6

RAIL14COM0441AA

7

5. Connect the engine ground terminal.

6. Connect the terminals and connectors on the starter.

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Engine - Engine and crankcase

7. Connect the engine connector (X6).

RAIL14COM0440AA

8

RAIL14COM0439AA

9

8. Install the hose (38) with the clamps (35).

9. Install the engine oil drain hose (37) on the fitting.

RAIL14COM0438AA

10

RAIL14COM0437AA

11

10. Install the hose (36) with the clamps (35).

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Engine - Engine and crankcase

11. Connect the connector (X50).

RAIL14COM0436AA

12

RAIL14COM0435AA

13

RAIL14COM0434AA

14

RAIL14COM0433AA

15

12. Connect the terminals on the fuses.

13. Install the hose (34) on the cooling pump.

14. Install the hoses (32) and (33) on the steering pump.

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Engine - Engine and crankcase

15. Connect the D+ terminal on the alternator.

RAIL14COM0432AA

16

RAIL14COM0430AA

17

RAIL14COM0429AA

18

RAIL14COM0428AA

19

16. Install the bracket (30) and differential lock valve (31) assembly with the hardware removed earlier.

17. Install the hose (29) on the engine with the clamps removed earlier.

18. Install the hoses (27) and (28) on the expansion tank (26).

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Engine - Engine and crankcase

19. Connect the connector to the coolant level sensor (S36).

RAIL14COM0427AA

20

RAIL14COM0426AA

21

RAIL14COM0425AA

22

RAIL14COM0424AA

23

20. Install the bracket (24) and filter assemblies with attaching hardware (28) removed earlier.

21. Install the hoses (22) and (23) on the filter assemblies.

22. Connect the connector on the Water in fuel switch (S38).

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Engine - Engine and crankcase

23. Connect the fuel pressure sensor connector.

RAIL14COM0423AA

24

RAIL14COM0422AA

25

RAIL14COM0420AA

26

RAIL14COM0419AA

27

24. Connect the connector (X12) on the fuel pump.

25. Install the duct (19) and gaskets (20) with the clamps (18).

26. Install the duct (17) on the turbocharger with the clamp (16).

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Engine - Engine and crankcase

27. Install the ducts (12), (13) and (14) and clamps (23) on the intercooler (10) and induction manifold with the clamps (5) and (11).

28. Secure the duct (12) with the clamp (15) and attaching hardware removed earlier.

RAIL14COM0417AA

28

RAIL14COM0418AA

29

RAIL14COM0416AA

30

RAIL14COM0415AA

31

29. Install the ducts (7), (8) and (9) and clamps (5) on the intercooler (10) and engine with the clamps (5) and (6).

30. Connect the connectors from Engine Control Unit (ECU).

31. Connect the connectors (4) on the bracket (3).

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Engine - Engine and crankcase

32. Install the bracket (3) with the attaching hardware removed earlier.

RAIL14COM0414AA

32

RAIL14COM0413AA

33

RAIL14COM0412AA

34

33. Install the ECU bracket (2).

34. Install the ECU (1) on the ECU bracket (2).

35. Secure the hoses and cables with the cable ties.

36. Install the travel pump (refer to Pump - Install the travel pump (29.218)).

37. Install the vibration pump for the rear drum (refer to Pump - Install the pump for rear drum vibrations (29.218)).

38. Install the vibration pump for the front drum (refer to Pump - Install the pump for front drum vibrations (29.218)).

39. Install the platform (refer to Cab and platform - Install (90.150) ).

40. Install the cab (refer to Cab - Install (90.150) ).

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Engine - Engine and crankcase

41. Open the fuel shut-off valves (21).

42. Fill the service fluids.

43. Start the engine and check for serviceability and leaks.

44. Top up the service fluids as necessary.

RAIL14COM0421AA

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35

Engine - Engine and crankcase

Engine - Troubleshooting Problem Engine does not start or is difficult to start

Possible Cause Not disconnected (if possible)

Fuel tank empty Fuel suction pipe blocked Below starting limit temperature Cold starting device Wrong SAE viscosity class of the engine lubricating oil Fuel quality does not comply with operating manual Battery defective or discharged Cable connection to starter loose or oxidized Starter defective or pinion does not engage Air filter clogged / turbocharger defective Air in fuel system Compression pressure too low Exhaust gas backpressure too high Injection line leaks Engine does not start and Engine electronics prevents starting diagnostic lamp flashes Engine starts, but runs Exhaust gas backpressure too high irregularly or fails Compression pressure too low Cold starting device Air in fuel system Fuel filter contaminated Fuel quality does not comply with operating manual Injector defective Injection line leaks Engine electronics has detected a system Speed changes are possible and diagnostic error and activates an equivalent speed lamp lights up Vent line blocked Engine becomes excessively hot.

Temperature warning system activates Wrong SAE viscosity class of the engine lubricating oil Lube oil cooler defective Lube oil filter contaminated on the air or lube oil side Lube oil level too high Lubricating oil level too low Injector defective Coolant heat exchanger soiled Defective cooling water pump (torn or loose V-belt) Low coolant Resistance in cooling system is too high / flow volume too low Cooling fan or exhaust thermostat defective, V-belt torn or loose Charge air line leaking Charge air cooler soiled Air filter clogged / turbocharger defective

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Correction Check coupling Tanks Check Check Check/replace Change the lubricating oil Change the fuel Check battery Check cable connections Check starter Check/replace Vent fuel system Check compression pressure Check Check injection line Check error according to error code and eliminate error if necessary Check Check compression pressure Check/replace Vent Clean Change the fuel Change Check injection line Check error according to error code and eliminate error if necessary Clean

Change the lubricating oil Check/replace Change Check lube oil level, if necessary drain off.

Fill up lube oil Change Clean Check whether torn or loose Fill up Check the cooling system Check/replace/tension Check charge air line Check/clean Check/replace

Engine - Engine and crankcase

Problem

Possible Cause Air filter maintenance switch / maintenance indicator defective Fan defective/V-rib belt torn or loose Exhaust gas backpressure too high Engine output is deficient Lube oil level too high Lubricating oil cooler fins soiled Fuel suction temperature too high Fuel quality does not comply with operating manual Air filter clogged / turbocharger defective Air filter maintenance switch / maintenance indicator defective Fan defective/V-rib belt torn or loose Charge air line leaking Charge air cooler soiled Resistance in cooling system is too high / flow volume too low Injection line leaks Injector defective Engine performs poorly Engine electronics reduce performance and diagnostic lamp lights Engine does not run on Injection line leaks all cylinders Injector defective Charge air line leaking Lube oil level too high Engine lubricating oil Lube oil level too high consumption excessive Excessive inclination of engine Crankcase breather No engine lubricating oil Lubricating oil level too low pressure or excessively low Excessive inclination of engine Wrong SAE viscosity class of the engine lubricating oil Lubricating oil in the Engine operated continuously with too low exhaust system a load (< 20-30%) Engine producing blue Lube oil level too high smoke Excessive inclination of engine Engine producing white Below starting limit temperature smoke Cold starting device Fuel quality does not comply with operating manual Injector defective Engine producing black Air filter clogged / turbocharger defective smoke Air filter maintenance switch / maintenance indicator defective Charge air line leaking Injector defective

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Correction Check/replace Check fan/V-belt, change if necessary Check Check lube oil level, if necessary drain off.

Clean Check the system Change the fuel Check/replace Check/replace Check fan/V-belt, change if necessary Check charge air line Clean Check the cooling system Check injection line Change Please contact your DEUTZ partner Check injection line Change Check charge air line Check lube oil level, if necessary drain off.

Check lube oil level, if necessary drain off.

Check engine mounting / reduce inclination Check/replace Fill up lube oil Check engine mounting / reduce inclination Change the lubricating oil Check load factor Check lube oil level, if necessary drain off.

Check engine mounting / reduce inclination Check Check/replace Change the fuel Change Check/replace Check/replace Check charge air line Change

Index Engine - 10 Engine and crankcase - 001 Engine - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Engine - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Engine - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Engine - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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Engine - 10 Fuel tanks - 216

DV209C DV210C

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Contents Engine - 10 Fuel tanks - 216

FUNCTIONAL DATA Fuel tanks Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Fuel tank Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Engine - Fuel tanks

Fuel tanks - Exploded view

RAIL14COM0805HA

1

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Engine - Fuel tanks

S. No 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

Description Fuel tank Bolt Washer Bushing Filler cap Bracket Bolt Lock washer Washer Plug Fuel level sensor Washer Bolt Sleeve Shim

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Engine - Fuel tanks

Fuel tank - Remove 1. Place a suitable drain collector of adequate capacity under the fuel tank drain.

2. Drain the fuel from the fuel tank.

NOTE: Approx drain volume: 210 L (55.5 US gal).

3. Disconnect the wires (319) and (341) from the fuel level sensor (10).

RAIL14COM0736AA

1

RAIL14COM0737AA

2

RAIL14COM0738AA

3

4. Close the fuel shut-off valves (1).

5. Disconnect the hoses (2) and (3) from the fuel shut-off valves (1).

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Engine - Fuel tanks

6. Remove the bolts, lock washers and washers (4) and brackets (5).

RAIL14COM0739AA

4

RAIL14COM0740AA

5

RAIL14COM0741AA

6

RAIL14COM0742AA

7

7. Remove the bolts and washers (6) and bushings, sleeves and shims (7).

8. Remove the fuel tank (8).

NOTICE: Use suitable lifting equipment. Approx weight of the fuel tank: 40 kg (88 lb).

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Engine - Fuel tanks

9. Remove the plug (9), fuel level sensor (10) and fuel shut-off valves (1) from the fuel tank (8).

RAIL14COM0743AA

8

RAIL14COM0744AA

9

10. Remove the sight gage (11) and fuel tank cap (12) from the fuel tank (8).

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Engine - Fuel tanks

Fuel tank - Install 1. Apply LOCTITE® 577™ on the contact surfaces of the sight gage (11) and fuel tank (8).

2. Install the sight gage (11) on the fuel tank (8).

3. Install the fuel tank cap (12) on the fuel tank (8).

RAIL14COM0744AA

1

RAIL14COM0743AA

2

RAIL14COM0741AA

3

4. Apply LOCTITE® 577™ on the contact surfaces of the plug (9), fuel level sensor (10) and fuel shut-off valves (1) and fuel tank (8).

5. Install the plug (9), fuel level sensor (10) and fuel shutoff valves (1) on the fuel tank (8).

6. Lift and place the fuel tank (8) in its correct position in the frame.

NOTICE: Use suitable lifting equipment. Approx weight of the fuel tank: 40 kg (88 lb).

7. Secure the fuel tank (8) on the frame with the bolts and washers (6) and bushings, sleeves and shims (7).

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Engine - Fuel tanks

8. Install the brackets (5) with the bolts, lock washers and washers (4).

RAIL14COM0739AA

4

RAIL14COM0740AA

5

RAIL14COM0737AA

6

RAIL14COM0738AA

7

9. Connect the hoses (2) and (3) to the fuel shut-off valves (1).

10. Open the fuel shut-off valves (1).

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Engine - Fuel tanks

11. Connect the wires (319) and (341) to the fuel level sensor (10).

12. Fill the fuel tank and check for any leaks.

RAIL14COM0736AA

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8

Index Engine - 10 Fuel tanks - 216 Fuel tank - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Fuel tank - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Fuel tanks - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - 10 Engine cooling system - 400

DV209C DV210C

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Contents Engine - 10 Engine cooling system - 400

SERVICE Radiator Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Engine - Engine cooling system

Radiator - Remove 1. Place a suitable drain collector under the coolant drain plug.

2. Remove the drain plug and drain the coolant.

NOTE: Approximate drain volume: 23 L (6.1 US gal).

RAIL14COM0514AA

1

RAIL14COM0411AA

2

RAIL14COM0542AA

3

RAIL14COM0485AA

4

3. Place a suitable drain collector under the hydraulic oil drain plug.

4. Remove the drain plug and drain the hydraulic oil.

NOTE: Approximate drain volume: 60 L (15.9 US gal).

5. Remove the radiator cover (1).

6. Remove the radiator cover (2).

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Engine - Engine cooling system

7. Disconnect the connector from the cooling fan solenoid valve (Y4).

8. Remove the hoses (3) and (5) from the solenoid valve.

9. Remove the hose (4) from the hydraulic motor.

RAIL14COM0657AA

5

RAIL14COM0658AA

6

RAIL14COM0659AA

7

RAIL14COM0668AA

8

10. Remove the bolts (7) which secure the fan bracket (6) on the radiator (5).

11. Remove the fan bracket and fan assembly (A).

12. Remove the bolts (8) which secure the fan cover (9) on the frame.

13. Remove the fan cover (9).

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Engine - Engine cooling system

14. Remove the clamp (11) and duct (10).

15. Remove the hoses (12), (13) and (14).

RAIL14COM0417AA

9

16. Remove the clamp (15).

RAIL14COM0670AA

10

RAIL14COM0544AA

11

RAIL14COM0671AA

12

17. Remove the hoses (16) and (17) from the radiator (18).

18. Remove the hose (19) from the radiator (18).

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Engine - Engine cooling system

19. Remove the hoses (20) and (21) from the radiator (18).

RAIL14COM0545AA

13

RAIL14COM0672AA

14

RAIL14COM0674AA

15

RAIL14COM0547AA

16

20. Remove the bolts (22) and brake off valve (23).

21. Remove the bolts (24) and washers (25) and (26).

22. Remove the vibration isolators (27).

23. Remove the bolts (24) and washers (25) and (26).

24. Remove the vibration isolators (27).

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Engine - Engine cooling system

25. Slide the radiator (18) out of the frame and remove.

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RAIL14COM0675AA

17

RAIL14COM0676AA

18

Engine - Engine cooling system

Radiator - Install 1. Using suitable lifting device, lift and position the radiator (18) in its correct position.

RAIL14COM0675AA

1

RAIL14COM0676AA

2

RAIL14COM0677AA

3

RAIL14COM0547AA

4

2. Install the vibration isolators (28) with the washers (25) and (26) and bolts (24).

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Engine - Engine cooling system

3. Install the vibration isolators (27) with the washers (25) and (26) and bolts (24).

RAIL14COM0674AA

5

RAIL14COM0673AA

6

RAIL14COM0672AA

7

RAIL14COM0545AA

8

4. Position the brake off valve (23) in its correct position.

5. Install the brake off valve (23) with the washers and bolts (22).

6. Install the hoses (20) and (21) on the radiator (18).

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Engine - Engine cooling system

7. Install the hose (19) on the radiator (18).

RAIL14COM0671AA

9

8. Install the hoses (16) and (17) on the radiator (18).

RAIL14COM0544AA

10

RAIL14COM0670AA

11

RAIL14COM0417AA

12

9. Install the clamp (15).

10. Install the duct (10) on the radiator with the clamp (11).

11. Install the hoses (12), (13) and (14).

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Engine - Engine cooling system

12. Install the fan cover (9) with the bolts (8).

RAIL14COM0668AA

13

RAIL14COM0658AA

14

RAIL14COM0657AA

15

RAIL14COM0485AA

16

13. Install the fan bracket and fan assembly (6) with the bolt (7).

14. Install the hose (4) on the hydraulic motor.

15. Install the hoses (3) and (5) on the solenoid valve.

16. Connect the connector on the cooling fan solenoid valve (Y4).

17. Install the radiator cover (2).

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Engine - Engine cooling system

18. Install the radiator cover (1).

RAIL14COM0542AA

19. Refill the hydraulic system.

20. Refill the engine coolant.

21. Start the machine and check for serviceability and leaks.

22. Top up the hydraulic system and coolant if necessary.

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17

Index Engine - 10 Engine cooling system - 400 Radiator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Radiator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 2014 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

CASE CONSTRUCTION policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved.

All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your CASE CONSTRUCTION Dealer.

47772910 15/12/2014 EN

SERVICE MANUAL Hydrostatic drive DV209C DV210C

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29

Contents Hydrostatic drive - 29

[29.218] Pump and motor components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.1

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Hydrostatic drive - 29 Pump and motor components - 218

DV209C DV210C

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Contents Hydrostatic drive - 29 Pump and motor components - 218

FUNCTIONAL DATA Pump Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Pump Remove the pump for front drum vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install the pump for front drum vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Remove the pump for rear drum vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install the pump for rear drum vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Remove the travel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install the travel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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Hydrostatic drive - Pump and motor components

Pump - Overview

RAIL14COM0804HA

1

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Hydrostatic drive - Pump and motor components

S. No 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

Description Engine Gasket Flange Steering pump Cooling pump Socket head cap screw Washer Clutch Mounting flange Lock washer Hexagonal screw Travel pump Vibration pump Hydraulic pump

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Hydrostatic drive - Pump and motor components

Pump - Remove the pump for front drum vibrations 1. Place a suitable drain container with adequate capacity under the hydraulic system drain plug.

2. Remove the drain plug and drain the hydraulic system.

RAIL14COM0449AA

1

RAIL14COM0585AA

2

RAIL14COM0586AA

3

RAIL14COM0587AA

4

3. Disconnect the connector from the solenoids Y7 and Y8.

4. Place a suitable drain collector with adequate capacity under the pump.

5. Remove the hose (2), (3), (4) and (5) form the pump (1) 6. Cover the ports with protective plugs.

7. Remove the bolts (6) which secures the pump (1).

8. Remove the pump (1).

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Hydrostatic drive - Pump and motor components

9. Check the O-ring for condition. Replace if necessary.

RAIL14COM0588AA

5

RAIL14COM0589AA

6

RAIL14COM0590AA

7

10. Remove the fittings (7).

11. Remove the fittings (8) and sensors (9).

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Hydrostatic drive - Pump and motor components

Pump - Install the pump for front drum vibrations 1. Install the sensors (9) and fittings (8) on the pump (1).

RAIL14COM0590AA

1

RAIL14COM0589AA

2

RAIL14COM0587AA

3

RAIL14COM0586AA

4

2. Install the fittings (7) on the pump (1).

3. Install the pump (1) with the bolts (6).

NOTICE: Apply LOCTITE® 620™ on the threads of the bolts (6).

4. Install the hoses (2), (3), (4) and (5) on the pump (1).

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Hydrostatic drive - Pump and motor components

5. Connect the connector from the solenoids Y7 and Y8.

RAIL14COM0585AA

5

RAIL14COM0449AA

6

6. Install the drain plug and fill the system.

7. Start the machine and check for serviceability and leaks.

8. Top-up the hydraulic system if necessary.

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Hydrostatic drive - Pump and motor components

Pump - Remove the pump for rear drum vibrations 1. Place a suitable drain container with adequate capacity under the hydraulic system drain plug.

2. Remove the vibrations pump for the front drum (refer to Pump - Remove the pump for front drum vibrations (29.218) ).

3. Remove the drain plug and drain the hydraulic system.

RAIL14COM0449AA

1

RAIL14COM0591AA

2

RAIL14COM0592AA

3

RAIL14COM0593AA

4

4. Disconnect the connector from the solenoids Y7 and Y8.

5. Place a suitable drain collector with adequate capacity under the pump.

6. Remove the hoses form the pump (1).

7. Cover the ports with protective plugs.

8. Remove the bolts (2) which secures the pump (1).

9. Remove the pump (1).

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Hydrostatic drive - Pump and motor components

10. Check the O-ring for condition. Replace if necessary.

RAIL14COM0594AA

5

RAIL14COM0595AA

6

RAIL14COM0596AA

7

11. Remove the fittings (7).

12. Remove the fittings (8) and sensors (9).

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Hydrostatic drive - Pump and motor components

Pump - Install the pump for rear drum vibrations 1. Install the sensors (5) and fittings (4) on the pump (1).

RAIL14COM0596AA

1

RAIL14COM0595AA

2

RAIL14COM0593AA

3

RAIL14COM0592AA

4

2. Install the fittings (3) on the pump (1).

3. Install the pump (1) with the bolts (2).

NOTICE: Apply LOCTITE® 620™ on the threads of the bolts (2).

4. Install the hoses on the pump (1).

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Hydrostatic drive - Pump and motor components

5. Connect the connector from the solenoids Y7 and Y8.

6. Install the vibrations pump for the front drum (refer to Pump - Install the pump for front drum vibrations (29.218) ).

RAIL14COM0591AA

5

RAIL14COM0449AA

6

7. Install the drain plug and fill the system.

8. Start the machine and check for serviceability and leaks.

9. Top-up the hydraulic system if necessary.

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Hydrostatic drive - Pump and motor components

Pump - Remove the travel pump 1. Place a suitable drain container with adequate capacity under the hydraulic system drain plug.

2. Remove the drain plug and drain the hydraulic system.

RAIL14COM0449AA

1

RAIL14COM0564AA

2

RAIL14COM0565AA

3

3. Remove the vibration pump (1) for the front drum (refer to Pump - Remove the pump for front drum vibrations (29.218)).

4. Remove the vibration pump (2) for the rear drum (refer to Pump - Remove the pump for rear drum vibrations (29.218)).

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Hydrostatic drive - Pump and motor components

5. Disconnect the connector from the solenoids Y11 and Y12.

RAIL14COM0570AA

4

RAIL14COM0571AA

5

RAIL14COM0572AA

6

RAIL14COM0573AA

7

6. Place a suitable drain collector of adequate capacity under the pump to collect any drained oil.

7. Make identification marks on the hoses and remove them from the fittings of the pump (3).

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Hydrostatic drive - Pump and motor components

8. Make identification marks on the hoses and remove them from the travel control unit (4).

RAIL14COM0574AA

8

RAIL14COM0622AA

9

9. Support the pump (3) on a suitable lifting device with adequate capacity.

NOTICE: Approximate weight of the pump: (243 lb).

110 kg

10. Remove the bolts (5).

11. Carefully remove the pump (3) from the engine compartment.

RAIL14COM0575AA

10

RAIL14COM0623AA

11

12. Remove the bolts (6).

13. Remove the flange (7).

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Hydrostatic drive - Pump and motor components

14. Remove the travel control unit (4) and fittings (8) and (9) from the pump (3).

RAIL14COM0576AA

12

RAIL14COM0577AA

13

RAIL14COM0624AA

14

15. Remove the fittings (10) and (11) from the pump (3).

16. Remove the gear (12) from the pump (3).

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Hydrostatic drive - Pump and motor components

Pump - Install the travel pump 1. Install the gear (14) on the pump (3). Torque the bolts to 86 N·m (63.4 lb ft).

RAIL14COM0624AA

1

RAIL14COM0577AA

2

RAIL14COM0576AA

3

RAIL14COM0623AA

4

2. Install the fittings (10) and (11) on the pump (3).

3. Install the travel control unit (4) and fitting (8) and (9) on the pump (3).

4. Install the flange (7) on the pump (3) with the bolts (6).

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Hydrostatic drive - Pump and motor components

5. Lift the pump (3) with a lifting device of suitable capacity and place in its correct position.

RAIL14COM0575AA

5

RAIL14COM0622AA

6

RAIL14COM0574AA

7

6. Install the pump (3) on the engine with the bolts (5).

7. Remove the lifting device.

8. Install the hoses on their respective ports on the travel control unit (4).

NOTE: When installing the hoses, use the identification marks made during removal and connect them to their correct ports.

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Hydrostatic drive - Pump and motor components

9. Install the hoses on their respective ports on the pump (3).

NOTE: When installing the hoses, use the identification marks made during removal and connect them to their correct ports.

RAIL14COM0572AA

8

RAIL14COM0573AA

9

10. Connect the connectors from the solenoids Y11 and Y12.

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RAIL14COM0570AA

10

RAIL14COM0571AA

11

Hydrostatic drive - Pump and motor components

11. Install the vibration pump (2) for the rear drum (refer to Pump - Install the pump for rear drum vibrations (29.218)).

RAIL14COM0565AA

12

RAIL14COM0564AA

13

RAIL14COM0449AA

14

12. Install the vibration pump (1) for the front drum (refer to Pump - Install the pump for front drum vibrations (29.218)).

13. Install the drain plug and fill the hydraulic system.

14. Start the machine and check for serviceability and leaks.

15. Top-up the hydraulic system if necessary.

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Index Hydrostatic drive - 29 Pump and motor components - 218 Pump - Install the pump for front drum vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Pump - Install the pump for rear drum vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Pump - Install the travel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Pump - Remove the pump for front drum vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Pump - Remove the pump for rear drum vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Pump - Remove the travel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 2014 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

CASE CONSTRUCTION policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved.

All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your CASE CONSTRUCTION Dealer.

47772910 15/12/2014 EN

SERVICE MANUAL Hydraulic systems DV209C DV210C

47772910 15/12/2014

35

Contents Hydraulic systems - 35

[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.752] Hydraulic fan drive cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.353] Hydraulic travel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 [35.995] Compaction/vibration hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5

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Hydraulic systems - 35 Hydraulic systems - 000

DV209C DV210C

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Contents Hydraulic systems - 35 Hydraulic systems - 000

FUNCTIONAL DATA Hydraulic systems Hydraulic schema (DV209C - Low frequency models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic schema (DV209C - High frequency models) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Hydraulic schema (DV210C - Low frequency models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Hydraulic schema (DV210C - High frequency models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

(*) See content for specific models 47772910 15/12/2014

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic schema (DV209C - Low frequency models) S. No 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

Description Travel pump Front vibration pump Rear vibration pump Steering pump Cooling pump Front drum travel motor (left-hand side) Rear travel hydraulic motor (right-hand side) Rear vibration motor Cooling fan motor Steering cylinder Crab cylinder Edge cutter cylinder (optional) Front vibration motor RTM control module Power steering unit RTM and flushing block Brake block Edge cutter and crab control block Edge cutter switch Oil filter Radiator Reservoir Filler port Oil level sensor Sight gage Temperature sensor Priority valve Non-return valve Non-return valve Non-return valve Ball valve Ball valve Filling quick coupler (not used) Quick coupler for measurements

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Hydraulic systems - Hydraulic systems

RAIL14COM0784JA

1

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic schema (DV209C - High frequency models) DV209C

S. No 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

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Description Travel pump Front vibration pump Rear vibration pump Steering pump Cooling pump Front drum travel motor (left-hand side) Rear travel hydraulic motor (right-hand side) Rear vibration motor Cooling fan motor Steering cylinder Crab cylinder Edge cutter cylinder (optional) Front vibration motor RTM control module Power steering unit RTM and flushing block Brake block Edge cutter and crab control block Edge cutter switch Oil filter Radiator Reservoir Filler port Oil level sensor Sight gage Temperature sensor Priority valve Non-return valve Non-return valve Non-return valve Ball valve Ball valve Filling quick coupler (not used) Quick coupler for measurements

Hydraulic systems - Hydraulic systems

RAIL14COM0785JA

1

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Hydraulic systems - Hydraulic schema (DV210C - Low frequency models) S. No 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

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Description Travel pump Front vibration pump Rear vibration pump Steering pump Cooling pump Front drum travel motor (left-hand side) Rear travel hydraulic motor (right-hand side) Rear vibration motor Cooling fan motor Steering cylinder Crab cylinder Edge cutter cylinder (optional) Front vibration motor RTM control module Power steering unit RTM and flushing block Brake block Edge cutter and crab control block Edge cutter switch Oil filter Radiator Reservoir Filler port Oil level sensor Sight gage Temperature sensor Priority valve Non-return valve Non-return valve Non-return valve Ball valve Ball valve Filling quick coupler (not used) Quick coupler for measurements

Hydraulic systems - Hydraulic systems

RAIL14COM0786JA

1

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Hydraulic systems - Hydraulic schema (DV210C - High frequency models) S. No 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

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Description Travel pump Front vibration pump Rear vibration pump Steering pump Cooling pump Front drum travel motor (left-hand side) Rear travel hydraulic motor (right-hand side) Rear vibration motor Cooling fan motor Steering cylinder Crab cylinder Edge cutter cylinder (optional) Front vibration motor RTM control module Power steering unit RTM and flushing block Brake block Edge cutter and crab control block Edge cutter switch Oil filter Radiator Reservoir Filler port Oil level sensor Sight gage Temperature sensor Priority valve Non-return valve Non-return valve Non-return valve Ball valve Ball valve Filling quick coupler (not used) Quick coupler for measurements

Hydraulic systems - Hydraulic systems

RAIL14COM0787JA

1

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Index Hydraulic systems - 35 Hydraulic systems - 000 Hydraulic systems - Hydraulic schema (DV209C - High frequency models) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Hydraulic systems - Hydraulic schema (DV210C - Low frequency models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Hydraulic systems - Hydraulic schema (DV210C - High frequency models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Hydraulic systems - Hydraulic schema (DV209C - Low frequency models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

(*) See content for specific models 47772910 15/12/2014

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Hydraulic systems - 35 Reservoir, cooler, and filters - 300

DV209C DV210C

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Contents Hydraulic systems - 35 Reservoir, cooler, and filters - 300

SERVICE Oil reservoir Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Oil reservoir - Remove 1. Place a suitable drain collector with adequate capacity under the frame to collect the hydraulic oil.

NOTE: Approx. drain volume: 60 L (16 US gal).

2. Remove the drain plug and drain the hydraulic oil.

RAIL14COM0449AA

1

RAIL14COM0479AA

2

RAIL14COM0480AA

3

RAIL14COM0481AA

4

3. Disconnect the connector from Hydraulic tank float switch S13.

4. Remove the hose (1) from the filter.

5. Remove the hydraulic hose (2).

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6. Disconnect the hydraulic hose (3).

RAIL14COM0482AA

5

RAIL14COM0483AA

6

RAIL14COM0485AA

7

RAIL14COM0486AA

8

7. Remove the dipstick pipe (4).

8. Remove the cover (5).

9. Remove the bolts (6) and nuts (7).

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10. Remove the bolts (8).

RAIL14COM0487AA

9

11. Remove the reservoir (9).

RAIL14COM0488AA

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10

Hydraulic systems - Reservoir, cooler, and filters

Oil reservoir - Install 1. Place the reservoir (9) in its correct position in the engine compartment.

RAIL14COM0488AA

1

RAIL14COM0487AA

2

RAIL14COM0486AA

3

RAIL14COM0484AA

4

2. Secure the reservoir (9) in place with the bolts (8).

3. Install the bolts (6) and nut (7).

4. Apply LOCTITE® 598™ BLACK on the flanges of the dipstick pipe (4).

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5. Install the dipstick pipe (4) with the bolts removed earlier.

RAIL14COM0483AA

5

RAIL14COM0482AA

6

RAIL14COM0481AA

7

RAIL14COM0480AA

8

6. Install the hydraulic hose (3) on the reservoir.

7. Install the hydraulic hose (2).

8. Install the hose (1) on the filter.

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9. Connect the connector on hydraulic tank float switch S13.

RAIL14COM0479AA

9

10. Install the drain plug and fill the hydraulic system.

11. Start the machine and check for leaks and serviceability.

12. Top-up the hydraulic fluid if necessary.

RAIL14COM0449AA

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10

Index Hydraulic systems - 35 Reservoir, cooler, and filters - 300 Oil reservoir - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Oil reservoir - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Hydraulic systems - 35 Hydraulic fan drive cooling system - 752

DV209C DV210C

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Contents Hydraulic systems - 35 Hydraulic fan drive cooling system - 752

FUNCTIONAL DATA Hydraulic fan drive cooling system Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Fan pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Fan motor Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Hydraulic fan drive cooling system - Component identification The main components of the hydraulic cooling circuit are pump, hydraulic motor and radiator.

Cooling pump name plate.

Gear pump

RAIL14COM0678AA

1

RAIL14COM0679AA

2

RAIL14COM0680AA

3

RAIL14COM0681AA

4

Hydraulic motor

Radiator

Filter Filter element

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Fan pump - Remove 1. Place a suitable drain collector with adequate capacity under the frame.

NOTICE: Approximate drain volume: 60 L (15.85 US gal).

2. Remove the drain plug and drain the hydraulic oil.

RAIL14COM0449AA

1

RAIL14COM0662AA

2

RAIL14COM0663AA

3

RAIL14COM0664AA

4

3. Remove the hoses (1) and (2).

4. Remove the flanges (3) and (4).

5. Remove the bolts (5).

6. Remove the pump (6).

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Fan pump - Install 1. Check the sealing rings (7) for damage and condition.

Replace if necessary.

RAIL14COM0666AA

1

RAIL14COM0667AA

2

RAIL14COM0665AA

3

RAIL14COM0664AA

4

2. Check the O-rings (8) and (9) for damage and condition. Replace if necessary.

3. Place the pump (6) in its correct position.

4. Install the pump (6) with the bolts (5).

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5. Install the flanges (3) and (4) on the pump (6).

RAIL14COM0663AA

5

RAIL14COM0662AA

6

RAIL14COM0449AA

7

6. Install the hoses (1) and (2) on the pump (6).

7. Install the drain plug and fill the hydraulic system fluid.

8. Start the machine and check for leaks.

9. Top-up the hydraulic fluid if necessary.

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Fan motor - Remove 1. Remove the cover (1).

RAIL14COM0542AA

1

RAIL14COM0485AA

2

RAIL14COM0657AA

3

RAIL14COM0658AA

4

2. Remove the cover (2).

3. Disconnect the solenoid valve connector (3).

4. Disconnect the hoses (4), (5) and (6) from the hydraulic motor.

5. Remove the bolts (7) which secures the bracket (8).

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6. Remove the bracket (8) with the fan and motor assembly.

RAIL14COM0659AA

5

RAIL14COM0660AA

6

RAIL14COM0627AA

7

7. Remove the bolts (9) from the fan (10).

8. Remove the fan (10) from the motor (11).

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9. Remove the nut (12).

RAIL14COM0628AA

8

RAIL14COM0629AA

9

10. Remove the flange (13) with a puller.

RAIL14COM0630AA

10

RAIL14COM0661AA

11

11. Remove the bolts (14).

12. Remove the hydraulic motor (11) from the bracket (8).

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Fan motor - Install 1. Install the hydraulic motor (11) on the bracket (8) with the bolts (14).

RAIL14COM0661AA

1

RAIL14COM0629AA

2

RAIL14COM0628AA

3

2. Install the flange (13) with the nut (12).

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3. Install the fan (10) on the hydraulic motor (11) with the bolts (9).

RAIL14COM0627AA

4

RAIL14COM0660AA

5

RAIL14COM0659AA

6

RAIL14COM0658AA

7

4. Install the pre-assembled bracket (8) on the radiator with the bolts (7).

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5. Install the hoses (4), (5) and (6) on the hydraulic motor.

6. Connect the valve connector (3).

RAIL14COM0657AA

8

RAIL14COM0485AA

9

7. Install the cover (2).

8. Install the cover (1).

RAIL14COM0542AA

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10

Index Hydraulic systems - 35 Hydraulic fan drive cooling system - 752 Fan motor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Fan motor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Fan pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Fan pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic fan drive cooling system - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Hydraulic systems - 35 Hydraulic travel system - 353

DV209C DV210C

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Contents Hydraulic systems - 35 Hydraulic travel system - 353

SERVICE Travel motor Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Travel reduction gear Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Travel motor - Remove NOTE: The below procedure shows the removal of the rear travel motor (located on the right-hand side of the drum).

The procedure is the same to remove the front travel motor (located on the left-hand side of the drum).

1. Place a suitable drain collector with adequate capacity under the frame.

NOTICE: Approximate drain volume: 60 L (16 US gal).

2. Remove the drain plug and drain the hydraulic oil.

RAIL14COM0449AA

1

RAIL14COM0555AA

2

RAIL14COM0556AA

3

RAIL14COM0567AA

4

3. Supports the frame on both the sides.

4. Place suitable drain collectors with adequate capacity under the travel motor to be removed.

5. Drain the oil form the travel reduction gear.

6. Remove the hose (2) and (3) from the travel motor (1).

7. Remove the hose (4) and (5) from the travel motor (1).

8. Cover the ports with protective plugs.

9. Remove the bolts (6).

10. Remove the travel motor (1).

11. If the motor needs to be replaced, remove the flanges (7) from the motor (1).

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Travel motor - Install NOTE: The below procedure shows the installation of the rear travel motor (located on the right-hand side of the drum). The procedure is the same to install the front travel motor (located on the left-hand side of the drum).

1. If a new motor is to be installed, install the flanges (7) on the new motor (1).

2. Install the motor (1) on the travel reduction gearbox with the bolts (6).

RAIL14COM0567AA

1

RAIL14COM0556AA

2

RAIL14COM0449AA

3

3. Install the hoses (2) and (3) on the travel motor (1).

4. Install the hoses (4) and (5) on the travel motor (1).

5. Install the drain plug and fill the hydraulic system with oil.

6. Start the machine and check for serviceability and leaks.

7. Top-up the hydraulic system fluid if necessary.

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Travel reduction gear - Remove NOTE: The below procedure shows the removal of the rear travel reduction gearbox (located on the right-hand side of the drum). The procedure is the same to remove the front travel reduction gearbox (located on the left-hand side of the drum).

1. Place a suitable drain collector with adequate capacity under the frame.

NOTICE: Approximate drain volume: 60 L (16 US gal).

2. Remove the drain plug and drain the hydraulic oil.

RAIL14COM0449AA

1

RAIL14COM0555AA

2

RAIL14COM0557AA

3

3. Support the frame on both the sides with suitable supports.

4. Place a suitable drain container with adequate capacity under the travel reduction gearbox to be removed.

5. Drain the oil from the reduction gearbox.

6. Remove the brackets (6).

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7. Remove hoses (2) and (3) from the travel motor (1).

8. Remove hoses (4) and (5) from the travel motor (1).

9. Cover the ports with protective plugs.

RAIL14COM0556AA

4

RAIL14COM0568AA

5

RAIL14COM0569AA

6

RAIL14COM0558AA

7

10. Support the side bracket (7) with a suitable lifting device of adequate capacity.

NOTICE: The side bracket weighs approximately 200 kg (440 lb).

11. Remove the bolts (8) which attached the side bracket (7) on the cross member (9).

12. Remove the bolts (10) which attached the side bracket (7) on the frame.

13. Remove the bolts (12) which attaches the reduction gear (11) on the side bracket (7).

14. Remove the side bracket (7).

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15. Install the tool (T) on the reduction gearbox with the bolts removed earlier.

16. Support the tool (T) on a suitable lifting device with adequate capacity.

RAIL14COM0559AA

8

RAIL14COM0560AA

9

17. Remove the bolts (13) which attach the carrier on the vibration isolators (14).

18. Remove the carrier assembly (15) along with the reduction gearbox (11).

RAIL14COM0561AA

10

RAIL14COM0562AA

11

19. Remove the bolts (16) which attach the travel motor (1) on the reduction gearbox (11).

20. Remove the travel motor (1).

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21. Remove the bolts (17) which attach the reduction gearbox (11) on the carrier (15).

22. Remove the reduction gearbox (11) from the carrier (15).

RAIL14COM0563AA

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12

Hydraulic systems - Hydraulic travel system

Travel reduction gear - Install NOTE: The below procedure shows the removal of the rear travel reduction gearbox (located on the right-hand side of the drum). The procedure is the same to remove the front travel reduction gearbox (located on the left-hand side of the drum).

1. Install the reduction gearbox (11) on the carrier (15) with the bolts (17).

RAIL14COM0563AA

1

RAIL14COM0562AA

2

RAIL14COM0559AA

3

2. Install the travel motor (1) on the reduction gearbox (11) with the bolts (16).

3. Install the tool (T) on the reduction gearbox (11) with the bolts (12) removed earlier.

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4. Lift the carrier assembly (15) with a suitable lifting device of adequate capacity and position on the vibration isolators (14).

RAIL14COM0561AA

4

RAIL14COM0560AA

5

RAIL14COM0559AA

6

RAIL14COM0558AA

7

5. Install the carrier assembly (15) on the vibration isolators (14) with the bolts (13).

6. Remove the tool (T) from the reduction gearbox (11).

7. Lift the side bracket (7) with a suitable lifting device with adequate lifting capacity and place in its correct position.

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8. Install the side bracket (7) on the reduction gearbox (11) with the bolts (12).

RAIL14COM0569AA

8

RAIL14COM0568AA

9

9. Install the side bracket (7) on the cross member (9) with the bolts (8).

10. Install the side bracket (7) on the frame with the bolts (10).

11. Install the hoses (2) and (3) on the travel motor (1).

12. Install the hoses (4) and (5) on the travel motor (1).

RAIL14COM0556AA

10

RAIL14COM0557AA

11

13. Secure the hoses on the side bracket (7) with the bracket (6) and hardware removed earlier.

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14. Install the drain plug and fill the hydraulic system with oil.

15. Start the machine and check for serviceability and leaks.

16. Top-up the hydraulic system if necessary.

RAIL14COM0449AA

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12

Index Hydraulic systems - 35 Hydraulic travel system - 353 Travel motor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Travel motor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Travel reduction gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Travel reduction gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Hydraulic systems - 35 Compaction/vibration hydraulic system - 995

DV209C DV210C

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Contents Hydraulic systems - 35 Compaction/vibration hydraulic system - 995

FUNCTIONAL DATA Compaction/vibration hydraulic system Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Compaction/vibration hydraulic system Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Compaction/vibration motor Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Compaction/vibration hydraulic system - Component identification The main components of the vibration hydraulic circuit are vibration pumps and vibration hydraulic motors. Vibration pumps are mounted behind the travel pump. Vibration hydraulic motors are linked by means of couplings with vibrators - unbalanced shafts.

Front drum 1. Front vibrations pump 2. Front vibrations motor

RAIL14COM0790AA

1

RAIL14COM0620AA

2

RAIL14COM0790AA

3

RAIL14COM0620AA

4

Rear drum 3. Rear vibrations pump 4. Rear vibrations motor

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Hydraulic systems - Compaction/vibration hydraulic system

Compaction/vibration hydraulic system - Install 1. Measure the distance "A" (distance between the gear on the vibration shaft and flange surface) 2. Measure the distances "D" and "E" on the motor.

3. Measure the distance "C" of the gear.

4. With the above dimensions, calculate the number of shims (16) and washers (17) to be used with the formula: X = A - 4 - D - (C-E) 5. Heat the bushing (14) and gear (12) to 200 °C (392 °F).

6. Install the heated bushing (14), shims (16), washers (17) and gear (15) on the motor shaft.

RAIL14COM0621AA

1

RAIL14COM0791AA

2

RAIL14COM0583AA

3

RAIL14COM0582AA

4

7. Measure the distance "B".

8. Make sure the A - B is equal to 4 mm (0.16 in). Adjust the number of shims and washers if necessary.

Once the play of 4 mm (0.16 in) is achieved: NOTICE: Apply LOCTITE® 262™ to the threads of the bolt (15) before installation.

9. Install the bushing (14) on the shaft with the bolts (15).

10. Install the gear (12) on the motor shaft with the shims (16), washer (17) and bolt (13).

NOTICE: Apply LOCTITE® 620™ to the threads of the bolt (13) before installation.

11. Make sure that the O-ring (11) is installed on the motor.

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Hydraulic systems - Compaction/vibration hydraulic system

12. Install the vibrations motor (10) with the bolts (9).

Torque the bolts to 67 N·m (49.4 lb ft).

NOTICE: Apply LOCTITE® 262™ to the threads of the bolt (9) before installation.

RAIL14COM0580AA

5

RAIL14COM0625AA

6

RAIL14COM0579AA

7

13. Install the fittings (5), (6), (7) and (8) on the motor (10).

14. Install the hoses (1), (2), (3) and (4) on the fittings.

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Hydraulic systems - Compaction/vibration hydraulic system

Compaction/vibration motor - Remove 1. Place a suitable drain container with adequate capacity under the vibrations motors to be removed.

RAIL14COM0578AA

1

RAIL14COM0579AA

2

RAIL14COM0625AA

3

RAIL14COM0580AA

4

2. Remove the hoses (1), (2), (3) and (4).

3. Remove the fittings (5), (6), (7) and (8).

4. Remove the bolts (9) which attaches the vibration motor (10).

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Hydraulic systems - Compaction/vibration hydraulic system

5. Remove the vibrations motor (10).

RAIL14COM0581AA

5

RAIL14COM0582AA

6

RAIL14COM0583AA

7

RAIL14COM0584AA

8

6. Check the seal ring (11) for condition. Replace if necessary.

7. Immerse the motor (1) in water and heat the gear (12) to 250 °C (482 °F).

NOTE: Immersing in water while heating avoids the damage to the seals.

8. Remove the bolt (15).

9. Remove the bolt (13) which attaches the gear (12) and bushing (14).

10. Remove the gear (12) and bushing (14) with a puller.

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Compaction/vibration motor - Install 1. Measure the distance “A” (distance between the gear on the vibration shaft and flange surface) 2. Measure the distances “D” and “E” on the motor.

3. Measure the distance “C” of the gear.

4. With the above dimensions, calculate the number of shims (16) and washers (17) to be used with the formula: X = A - 4 - D - (C-E) 5. Heat the bushing (14) and gear (12) to 200 °C (392 °F).

6. Install the heated bushing (14), shims (16), washers (17) and gear (15) on the motor shaft.

RAIL14COM0621AA

1

RAIL14COM0791AA

2

RAIL14COM0583AA

3

RAIL14COM0582AA

4

7. Measure the distance “B”.

8. Make sure the A - B is equal to 4 mm (0.16 in). Adjust the number of shims and washers if necessary.

Once the play of 4 mm (0.16 in) is achieved: NOTICE: Apply LOCTITE® 262™ to the threads of the bolt (15) before installation.

9. Install the bushing (14) on the shaft with the bolts (15).

10. Install the gear (12) on the motor shaft with the shims (16), washer (17) and bolt (13).

NOTICE: Apply LOCTITE® 620™ to the threads of the bolt (13) before installation.

11. Make sure that the O-ring (11) is installed on the motor.

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12. Install the vibrations motor (10) with the bolts (9).

Torque the bolts to 67 N·m (49.4 lb ft).

NOTICE: Apply LOCTITE® 262™ to the threads of the bolt (9) before installation.

RAIL14COM0580AA

5

RAIL14COM0625AA

6

RAIL14COM0579AA

7

13. Install the fittings (5), (6), (7) and (8) on the motor (10).

14. Install the hoses (1), (2), (3) and (4) on the fittings.

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Compaction/vibration motor - Adjust The pulse sensor should be adjusted every time the sensor is replaced.

Adjust the pulse sensor as follows: 1. Apply thread lock sealant on the threads of the sensor lock nut.

2. Install the pulse sensor (1) in the vibration motor until it touches the ring (2).

3. Loosen the pulse sensor one and half turn so the clearance “X” = 1.5 mm (0.06 in).

4. Tighten the locknut.

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RAIL14COM0781AA

1

RAIL14COM0783AC

2

Index Hydraulic systems - 35 Compaction/vibration hydraulic system - 995 Compaction/vibration hydraulic system - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Compaction/vibration hydraulic system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Compaction/vibration motor - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Compaction/vibration motor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Compaction/vibration motor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 2014 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

CASE CONSTRUCTION policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved.

All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your CASE CONSTRUCTION Dealer.

47772910 15/12/2014 EN

SERVICE MANUAL Frames and ballasting DV209C DV210C

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Contents Frames and ballasting - 39

[39.100] Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1 [39.500] Vibratory roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.2

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Frames and ballasting - 39 Frame - 100

DV209C DV210C

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Contents Frames and ballasting - 39 Frame - 100

FUNCTIONAL DATA Articulation frame pivot Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Articulation frame pivot Remove the articulation joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install the articulation joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Disassemble the articulation joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Assemble the articulation joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Remove the pivot arm bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Install the pivot arm bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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Frames and ballasting - Frame

Articulation frame pivot - Exploded view

RAIL14COM0808GA

S. No 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

1

Description Bracket Bush Sealing ring Bearing Pin Lock washer Locknut Grease fitting Bolt Sleeve Cap screw Arm Bearing

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Frames and ballasting - Frame

14.

15.

16.

17.

18.

19.

20.

21.

Bushing Bearing cover Bracket Bolt Washer Lock plate Bolt Washer

RAIL14COM0809FA

S. No 1.

2.

3.

4.

5.

2

Description Yoke Shim Bracket Spring washer Bolt

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Frames and ballasting - Frame

RAIL14COM0811GA

S. No 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

3

Description Bracket Hose clamps Shim Plug Bolt Washer Seal ring Snap ring Bearing Arm Hexagonal screw Spring washer Lock plate Bolt Nut 47772910 15/12/2014

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Frames and ballasting - Frame

Articulation frame pivot - Remove the articulation joint 1. Remove the water tank (refer to Compaction - sprinkling/sprayer system - Remove the water tank (39.500)).

2. Remove the steering cylinder (refer to Cylinders - Remove the steering cylinder (41.216)).

3. Remove the crab cylinder (refer to Cylinders - Remove the crab cylinder (41.216)).

4. Support the front and rear frames on both sides.

RAIL14COM0494AA

1

RAIL14COM0495AA

2

5. Remove the bolt (1) and bracket (2).

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Frames and ballasting - Frame

6. Remove the bolts (3).

RAIL14COM0496AA

3

RAIL14COM0497AA

4

RAIL14COM0498AA

5

RAIL14COM0499AA

6

7. Remove the bolts (4).

8. Remove the bracket (4) from the front frame.

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Frames and ballasting - Frame

9. Lower the bracket on suitable supports.

RAIL14COM0506AA

7

RAIL14COM0507AA

8

RAIL14COM0500AA

9

10. Remove the hose clamps (6).

RAIL14COM0501AA

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10

Frames and ballasting - Frame

11. Remove the bracket (7).

RAIL14COM0502AA

11

RAIL14COM0503AA

12

RAIL14COM0504AA

13

RAIL14COM0505AA

14

12. Remove the hose (8).

13. Secure the steering joint with a lifting device of adequate capacity.

14. Remove the bolts (9).

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15. Remove the steering link.

RAIL14COM0511AA

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15

Frames and ballasting - Frame

Articulation frame pivot - Install the articulation joint 1. Lift the steering link with suitable lifting device of adequate capacity.

RAIL14COM0511AA

1

RAIL14COM0508AA

2

RAIL14COM0509AA

3

RAIL14COM0506AA

4

2. Place the steering link in its correct position.

3. Support the front side of the steering link on suitable supports.

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Frames and ballasting - Frame

4. Install the steering link on the rear frame with the bolts (9) removed earlier.

RAIL14COM0505AA

5

RAIL14COM0503AA

6

RAIL14COM0502AA

7

5. Install the hose (8).

6. Install the bracket (7) with the attaching hardware removed earlier.

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Frames and ballasting - Frame

7. Install the hose clamps (6).

RAIL14COM0500AA

8

RAIL14COM0501AA

9

8. Install the steering link on the front frame with the bolts (3) removed earlier.

9. Torque the bolts to 725 N·m (535 lb ft).

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RAIL14COM0496AA

10

RAIL14COM0497AA

11

Frames and ballasting - Frame

10. Install the bracket (2) with the bolt (1) removed earlier.

11. Install the crab cylinder (refer to Cylinders - Install the crab cylinder (41.216)).

12. Install the steering cylinder (refer to Cylinders - Install the steering cylinder (41.216)).

13. Install the water tank (refer to Compaction - sprinkling/sprayer system - Install the water tank (39.500)).

14. Start the machine and check for serviceability and leaks.

RAIL14COM0495AA

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12

Frames and ballasting - Frame

Articulation frame pivot - Disassemble the articulation joint 1. Remove the steering link (refer to Articulation frame pivot - Remove the articulation joint (39.100)).

RAIL14COM0511AA

1

RAIL14COM0515AA

2

RAIL14COM0516AA

3

Front bearing 2. Remove the bolts (2) and lock-plates (1).

3. Remove the bolt (3).

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4. Install a M20x150 bolt in place of bolt (3).

5. Drive out the bolt (4) with a hammer.

RAIL14COM0517AA

4

RAIL14COM0518AA

5

RAIL14COM0516AA

6

RAIL14COM0520AA

7

6. Remove the bolts (5).

7. Remove the bushing (7) from the bracket (6).

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8. Remove the sleeve (8) to access the bolts (9).

9. Remove the bolts (9).

RAIL14COM0522AA

8

RAIL14COM0523AA

9

10. Drive out the bearing assembly (10) from the link arm (11) with a hammer and punch.

11. Remove the bearing (12).

RAIL14COM0524AA

10

RAIL14COM0525AA

11

12. Drive out the bushing (13).

13. Remove the bearing (10) and bearing cover (14).

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Frames and ballasting - Frame

Rear bearing 14. Remove the steering link (refer to Articulation frame pivot - Remove the articulation joint (39.100)).

15. Secure the steering link upright with a lifting device of adequate capacity.

RAIL14COM0526AA

12

RAIL14COM0527AA

13

RAIL14COM0529AA

14

RAIL14COM0530AA

15

16. Remove the nut (1) and lock washer (2).

17. Remove the bolts (4) from the yoke (5) on both the sides of the link arm (6).

18. Remove the link arm (6) from the bracket (7).

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19. Drive out the pin (3) from the bushing (8).

RAIL14COM0531AA

16

RAIL14COM0532AA

17

RAIL14COM0533AA

18

RAIL14COM0534AA

19

20. Remove the bushing (8).

21. Remove the bearing (9).

22. Remove the bushing from the other side of the pin (3) with a press.

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23. Drive out the bearing race (10) from the link arm.

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RAIL14COM0535AA

20

RAIL14COM0536AA

21

Frames and ballasting - Frame

Articulation frame pivot - Assemble the articulation joint Rear bearing 1. Secure the steering link upright with a lifting device of adequate capacity.

RAIL14COM0526AA

1

RAIL14COM0536AA

2

RAIL14COM0534AA

3

RAIL14COM0533AA

4

2. Install the bearing races (10) on both ends of the link arm (6) with a press.

3. Install the bushing (8) on one end of the pin (3) with a press.

4. Install the bearing (9) on the bearing races.

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Frames and ballasting - Frame

5. Insert the pin (3) on the link arm (6) and secure the other end of the pin with the bushing (8).

RAIL14COM0531AA

5

RAIL14COM0529AA

6

RAIL14COM0530AA

7

RAIL14COM0527AA

8

6. Install the pre-assembled link arm (6) on the bracket (7) with the yokes (5) and bolts (4).

7. Install the lock washer (2) and nut (1).

8. Install the steering link (refer to Articulation frame pivot - Install the articulation joint (39.100)).

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Frames and ballasting - Frame

Front bearing 9. Install the bearing (10) and bearing cover (14) on the bushing (13).

RAIL14COM0525AA

9

10. Install the bearing assembly (10) and bearing (12) on the bearing link arm (11).

RAIL14COM0524AA

10

RAIL14COM0522AA

11

RAIL14COM0521AA

12

11. Secure the bearing assembly (10) on the link arm (11) with the bolts (9).

12. Glue the sleeve (8) on the link arm (11), so that the sleeve covers all the bolts (9).

13. Apply grease on the surfaces of the bracket (6).

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Frames and ballasting - Frame

14. Place the link arm (11) on the bracket (6).

15. Slide the sleeve (7) to its correct position.

RAIL14COM0520AA

13

RAIL14COM0516AA

14

RAIL14COM0518AA

15

RAIL14COM0516AA

16

16. Secure the bushing (13) on the bracket (6) with the bolts (5) removed earlier.

17. Install the special bolt (4) on the bracket (6) with the bolts (3) removed earlier.

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Frames and ballasting - Frame

18. Secure the special bolt (4) with the lock-plate (1) and bolts (2).

19. Reinstall the steering link (refer to Articulation frame pivot - Install the articulation joint (39.100)).

RAIL14COM0515AA

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17

Frames and ballasting - Frame

Articulation frame pivot - Remove the pivot arm bearings 1. Support the front and rear frame on both sides.

RAIL14COM0494AA

1

RAIL14COM0537AA

2

RAIL14COM0538AA

3

RAIL14COM0539AA

4

Rear bearings 2. Remove the bolts (1) and lock-plate (2).

3. Remove the pin (3).

4. Remove the arm (4) from the bracket.

5. Remove the seals (5) from both the sides of the arm (4).

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Frames and ballasting - Frame

6. Remove the snap ring (6).

RAIL14COM0540AA

5

RAIL14COM0541AA

6

RAIL14COM0494AA

7

RAIL14COM0551AA

8

7. Drive out the bearing (7) with a hammer and punch.

Front bearings 8. Support the front and rear frame on both sides.

9. Remove the clamps (10) and hardware which secures the hoses and cables on the arm.

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Frames and ballasting - Frame

10. Drain the coolant is a suitable container with adequate capacity.

NOTE: Approximate drain volume: 23 L (6 US gal).

RAIL14COM0514AA

9

11. Remove the radiator covers.

RAIL14COM0485AA

10

RAIL14COM0543AA

11

RAIL14COM0544AA

12

12. Remove the duct (1).

13. Remove the coolant hose (2).

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Frames and ballasting - Frame

14. Remove the duct (3).

15. Remove the coolant hose (4).

RAIL14COM0545AA

13

RAIL14COM0546AA

14

RAIL14COM0547AA

15

RAIL14COM0548AA

16

16. Remove the radiator suspension mounts (5).

17. Move the radiator (6) to get access to the front pin.

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Frames and ballasting - Frame

18. Remove the bolts (7) and lock-plates (8).

RAIL14COM0549AA

17

RAIL14COM0550AA

18

RAIL14COM0552AA

19

RAIL14COM0553AA

20

19. Remove the pin (9).

20. Remove the arm (11).

21. Remove the seals (12) from the both sides of the arm (11).

22. Remove the snap ring (13) from both the sides of the arm (11).

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23. Drive out the bearing (14) with a hammer and punch.

RAIL14COM0554AA

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21

Frames and ballasting - Frame

Articulation frame pivot - Install the pivot arm bearings Front bearings 1. Install the bearing (7) on the arm (4) with a hammer and punch.

RAIL14COM0541AA

1

RAIL14COM0540AA

2

RAIL14COM0539AA

3

RAIL14COM0538AA

4

2. Secure the bearing with the snap ring (6).

3. Fix the seal rings (5) on both the sides of the arm (4) with glue.

4. Install the pin (3).

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Frames and ballasting - Frame

5. Secure the pin (3) with the lock-plate (2) and bolts (1).

RAIL14COM0537AA

5

RAIL14COM0554AA

6

RAIL14COM0553AA

7

RAIL14COM0552AA

8

Rear bearings 6. Install the bearing (14) on the arm (11).

7. Secure the bearing with snap rings (13) on both the sides.

8. Glue the seal ring on both the sides of the arm (11).

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9. Install the front end of the arm on the front frame with the pin (9).

RAIL14COM0550AA

9

10. Secure the pin (9) with the lock-plates (8) and bolts (7).

RAIL14COM0549AA

10

RAIL14COM0548AA

11

11. Move the radiator (6) to its correct position.

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Frames and ballasting - Frame

12. Install the radiator mounts with the hardware removed earlier.

RAIL14COM0547AA

12

RAIL14COM0546AA

13

RAIL14COM0545AA

14

RAIL14COM0544AA

15

13. Install the duct (4) and coolant tube (3) to the radiator.

14. Install the coolant hose (2).

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Frames and ballasting - Frame

15. Install the duct (1).

RAIL14COM0543AA

16

RAIL14COM0485AA

17

RAIL14COM0551AA

18

16. Install the radiator covers.

17. Secure the hoses and cables on the arm with the clamps (10) and hardware removed earlier.

18. Refill the engine coolant.

19. Start the engine and check for serviceability and leaks.

20. Top up the coolant if necessary.

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Index Frames and ballasting - 39 Frame - 100 Articulation frame pivot - Assemble the articulation joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Articulation frame pivot - Disassemble the articulation joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Articulation frame pivot - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Articulation frame pivot - Install the articulation joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Articulation frame pivot - Install the pivot arm bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Articulation frame pivot - Remove the articulation joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Articulation frame pivot - Remove the pivot arm bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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Frames and ballasting - 39 Vibratory roller - 500

DV209C DV210C

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Contents Frames and ballasting - 39 Vibratory roller - 500

SERVICE Compaction - sprinkling/sprayer system Remove the sprinkler pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install the sprinkler pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Remove the water tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install the water tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Damping system - vibration isolators Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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Frames and ballasting - Vibratory roller

Compaction - sprinkling/sprayer system - Remove the sprinkler pumps 1. Close the valve (1).

RAIL14COM0745AA

1

RAIL14COM0746AA

2

RAIL14COM0747AA

3

RAIL14COM0748AA

4

2. Remove the bolt (2).

3. Remove the cover (3).

4. Disconnect the connector (X20).

5. Remove the hoses (4).

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6. Remove the bolts (5).

7. Remove the pump (6).

8. Follow Steps 1 to Step 7 to remove the second pump.

RAIL14COM0749AA

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5

Frames and ballasting - Vibratory roller

Compaction - sprinkling/sprayer system - Install the sprinkler pumps 1. Install the pump (6) with the bolts (5).

RAIL14COM0749AA

1

RAIL14COM0748AA

2

RAIL14COM0747AA

3

RAIL14COM0746AA

4

2. Install the hoses (4).

3. Connect the connector (X20).

4. Install the cover (3) with the bolt (2).

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5. Open the valve (1) and check the system for serviceability and leaks.

6. Follow Steps 1 to Step 5 to install the second pump.

RAIL14COM0745AA

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5

Frames and ballasting - Vibratory roller

Compaction - sprinkling/sprayer system - Remove the water tank 1. Remove the drain cap and drain water from the tank.

RAIL14COM0750AA

1

RAIL14COM0751AA

2

RAIL14COM0752AA

3

RAIL14COM0753AA

4

2. Disconnect the connector (A) from the water level sensor (S16).

3. Remove the hose (1).

4. Remove the hose (2).

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Frames and ballasting - Vibratory roller

5. Remove the attaching hardware (3).

6. Remove the cover (4).

RAIL14COM0754AA

5

RAIL14COM0755AA

6

RAIL14COM0756AA

7

RAIL14COM0757AA

8

7. Remove the bolts (5), lock washers (6) and washers (7).

8. Remove the bushing (8) and sleeve (9).

9. Remove the bolts (10) and washers (11).

10. Remove the plates (12).

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Frames and ballasting - Vibratory roller

11. Lift and remove the tank with a suitable lifting device of adequate capacity.

NOTICE: Approximate tank weight: 80 kg (176 lb) 12. Remove the plugs, necks, water level sensor, sight gage and filler caps from the tank.

RAIL14COM0759AA

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9

Frames and ballasting - Vibratory roller

Compaction - sprinkling/sprayer system - Install the water tank 1. Apply LOCTITE® 5331 on the contact surfaces of the plugs, necks, water level sensor and sight gage and the water tank.

2. Install the plugs, necks, water level sensor, sight gage and filler caps on the new tank.

3. Lift the tank with a suitable lifting equipment of adequate capacity and place it in its correct position on the frame.

NOTICE: Approximate tank weight: 80 kg (176 lb)

RAIL14COM0759AA

1

RAIL14COM0756AA

2

RAIL14COM0757AA

3

RAIL14COM0755AA

4

4. Secure the tank on the frame with the plates (12), washers (11) and bolts (10).

5. Secure the tank with the sleeve (9), bushing (8), washers (7), lock washers (6) and bolts (5).

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Frames and ballasting - Vibratory roller

6. Secure the tank with the cover (4) and attaching hardware (3) removed earlier.

RAIL14COM0754AA

5

RAIL14COM0753AA

6

RAIL14COM0752AA

7

RAIL14COM0751AA

8

7. Install the hose (2).

8. Install the hose (1).

9. Connect the connector (A) t the water level sensor (S16).

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10. Install the drain cap and fill the water tank.

11. Check the system for leaks and serviceability.

RAIL14COM0750AA

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9

Frames and ballasting - Vibratory roller

Damping system - vibration isolators - Remove Vibration motor side 1. Lift the machine and place suitable supports under the frame.

RAIL14COM0650AA

1

RAIL14COM0651AA

2

RAIL14COM0682AA

3

RAIL14COM0683AA

4

2. Remove the bolts (1).

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Frames and ballasting - Vibratory roller

3. Remove the bolts (2) which attaches the vibration isolators (3) on the drum.

RAIL14COM0652AA

5

RAIL14COM0653AA

6

RAIL14COM0650AA

7

RAIL14COM0651AA

8

4. Remove the vibration isolator (3).

Travel motors side 5. Lift the machine and place suitable supports under the frame.

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Frames and ballasting - Vibratory roller

6. Remove the bolts (1).

RAIL14COM0682AA

9

RAIL14COM0683AA

10

RAIL14COM0654AA

11

RAIL14COM0655AA

12

7. Remove the bolts (4) which attaches the vibration isolators (5) on the carrier assembly.

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Frames and ballasting - Vibratory roller

8. Remove the vibration isolator (5).

RAIL14COM0656AA

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13

Frames and ballasting - Vibratory roller

Damping system - vibration isolators - Install Vibration motor side 1. Place the vibration isolators (3) in its correct position.

RAIL14COM0653AA

1

RAIL14COM0652AA

2

RAIL14COM0682AA

3

RAIL14COM0683AA

4

2. Install the vibration isolators (3) with the bolts (2) removed earlier.

3. Install the bolts (1).

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Frames and ballasting - Vibratory roller

Travel motors side 4. Place the vibration isolators (5) in its correct position.

RAIL14COM0656AA

5

RAIL14COM0654AA

6

RAIL14COM0655AA

7

5. Install the vibration isolators (5) with the bolts (4) removed earlier.

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Frames and ballasting - Vibratory roller

6. Install the bolts (1).

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RAIL14COM0682AA

8

RAIL14COM0683AA

9

Index Frames and ballasting - 39 Vibratory roller - 500 Compaction - sprinkling/sprayer system - Install the sprinkler pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Compaction - sprinkling/sprayer system - Install the water tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Compaction - sprinkling/sprayer system - Remove the sprinkler pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Compaction - sprinkling/sprayer system - Remove the water tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Damping system - vibration isolators - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Damping system - vibration isolators - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 2014 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

CASE CONSTRUCTION policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved.

All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your CASE CONSTRUCTION Dealer.

47772910 15/12/2014 EN

SERVICE MANUAL Steering DV209C DV210C

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Contents Steering - 41

[41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1 [41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 [41.206] Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3 [41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.4

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Steering - 41 Steering control - 101

DV209C DV210C

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Contents Steering - 41 Steering control - 101

FUNCTIONAL DATA Steering control Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Steering control Remove the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Power steering wheel Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Steering column Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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Steering - Steering control

Steering control - Exploded view

RAIL14COM0810HA

1

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Steering - Steering control

S. No 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Description Display Steering wheel Steering column Bolt Washer Cover Steering control unit Bolt Banjo bolt Copper washer Hose Fitting

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Steering - Steering control

Steering control - Component identification The machine is provided with a hydrostatically controlled joint that allows the mutual turning of the front and rear frame.

The hydraulic steering circuit includes a steering pump, a linear hydraulic motor of the steering and the crab, a filter and a control unit.

RAIL14COM0450AA

1

RAIL14COM0451AA

2

RAIL14COM0452AA

3

RAIL14COM0453AA

4

Hydraulic cylinder

Hydraulic cylinder

Filter

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Steering - Steering control

Control unit

RAIL14COM0454AA

Technical data of the manufacturer Control unit Steering pump delivery Working pressure Weight

16 cm³/rev (1 in³/rev) 175 bar (2538 psi) 5 kg (11 lb)

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5

Steering - Steering control

Steering control - Remove the display 1. Remove the bolts (1).

RAIL14COM0764AA

1

RAIL14COM0765AA

2

RAIL14COM0766AA

3

2. Make identification marks and disconnect the connectors (2) and (3) from the display.

3. Remove the display (4).

4. Remove the bolts (6).

5. Remove the display holder (5).

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Steering - Steering control

Steering control - Install the display 1. Install the display holder (5) with the bolts (6).

RAIL14COM0766AA

1

RAIL14COM0765AA

2

RAIL14COM0764AA

3

2. Connect the connectors (2) and (3) on the display (4).

NOTE: Make sure the connectors are connected to their respective receptacles on the display. Use the identification marks made during the removal process.

3. Install the display (4) on the display holder (5) with the bolts (1).

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Steering - Steering control

Power steering wheel - Remove 1. Remove the display.

2. Remove the nut (1).

3. Remove the steering wheel (2).

RAIL14COM0489AA

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1

Steering - Steering control

Power steering wheel - Install 1. Position the steering wheel (2) on the steering column.

2. Install the steering wheel (2) with the nut (1).

RAIL14COM0489AA

3. Install the display.

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1

Steering - Steering control

Steering column - Remove 1. Remove the display.

2. Remove the steering wheel (refer to Power steering wheel - Remove (41.101)).

3. Remove the cover (1)

RAIL14COM0490AA

1

RAIL14COM0491AA

2

RAIL14COM0492AA

3

RAIL14COM0493AA

4

4. Disconnect the connector (2).

5. Remove the covers (3).

6. Lift the steering column sleeve to get access to the bolts (4).

7. Remove the bolts (4).

8. Remove the steering column (5).

NOTICE: Carefully pull the cable (A) from the bracket, making sure not to damage the connector.

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Steering - Steering control

Steering column - Install 1. Insert the cable (A) into the bracket.

2. Place the steering column (5) in its correct position.

RAIL14COM0493AA

1

RAIL14COM0492AA

2

RAIL14COM0491AA

3

RAIL14COM0490AA

4

3. Apply LOCTITE® 262™ on the threads of the bolts (4).

4. Install the steering column (5) on the support with the bolts (4).

5. Install the steering column sleeve in its correct position.

6. Install the covers (3) with the bolts removed earlier.

7. Connect the connector (2).

8. Install the cover (1) with the bolts removed earlier.

9. Install the steering wheel (refer to Power steering wheel - Install (41.101)).

NOTICE: Carefully pull the cable (A) from the bracket, making sure not to damage the connector.

10. Install the display.

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Index Steering - 41 Steering control - 101 Power steering wheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Power steering wheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Steering column - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Steering column - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Steering control - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Steering control - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Steering control - Install the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Steering control - Remove the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Steering - 41 Hydraulic control components - 200

DV209C DV210C

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Contents Steering - 41 Hydraulic control components - 200

SERVICE Power steering control valve Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Steering - Hydraulic control components

Power steering control valve - Remove 1. Remove the covers (1) from both the sides of the steering column.

2. Place a suitable drain collector with adequate capacity under the steering column.

RAIL14COM0474AA

1

RAIL14COM0475AA

2

RAIL14COM0476AA

3

RAIL14COM0477AA

4

3. Disconnect the hoses (3), (4), (5), (6) and (7) from the steering column.

4. Cover the ports with protective plugs.

5. Lift the steering column sleeve to get access to the bolts (8).

6. Remove the bolts (8) and washers.

7. Remove the steering column (9).

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Steering - Hydraulic control components

8. Remove the bolts (10) and washers.

9. Remove the steering control unit.

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Steering - Hydraulic control components

Power steering control valve - Install 1. Install the steering control unit on the bracket with the bolts (10) and washers.

RAIL14COM0477AA

1

RAIL14COM0476AA

2

RAIL14COM0475AA

3

RAIL14COM0474AA

4

2. Install the steering column (9) on the bracket with the bolts (8) and washers.

3. Install the hoses (3), (4), (5), (6) and (7) on the steering control unit.

4. Install the covers (1) on both the sides of the steering column..

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Index Steering - 41 Hydraulic control components - 200 Power steering control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Power steering control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Steering - 41 Pump - 206

DV209C DV210C

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Contents Steering - 41 Pump - 206

SERVICE Pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Pump - Remove 1. Place a suitable drain collector with adequate capacity under the frame to collect the hydraulic oil.

NOTE: Approximate drain volume: 60 L (16 US gal).

2. Remove the drain plug and drain the hydraulic oil.

RAIL14COM0449AA

1

RAIL14COM0455AA

2

RAIL14COM0456AA

3

RAIL14COM0457AA

4

3. Remove the hydraulic hose (1) from the flange.

4. Remove the hydraulic hose (2) from the T-fitting.

5. Remove the hose flange (4) and flange, T-fitting and quick coupling assembly (3).

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6. Check the seal rings for condition. Replace if necessary.

RAIL14COM0458AA

5

RAIL14COM0459AA

6

RAIL14COM0460AA

7

RAIL14COM0461AA

8

7. Remove the bolts (5).

8. Remove the pump (6).

9. Check the seals (7) for condition. Replace if necessary.

10. Check the seals (8). Replace if damaged.

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Pump - Install 1. Install the pump (6) with the bolts (5).

RAIL14COM0459AA

1

RAIL14COM0457AA

2

RAIL14COM0456AA

3

RAIL14COM0455AA

4

2. Install the flange (4) on the pump (6).

3. Install the flange, T-fitting and quick coupling assembly (3) on the pump (6).

4. Install the hose (2) on the T-fitting.

5. Install the hose (1) on the flange.

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6. Install the drain plug and fill the hydraulic fluid.

7. Start the machine and check for serviceability and leaks.

8. Top up the hydraulic system fluid if necessary.

RAIL14COM0449AA

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5

Index Steering - 41 Pump - 206 Pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Steering - 41 Cylinders - 216

DV209C DV210C

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Contents Steering - 41 Cylinders - 216

FUNCTIONAL DATA Cylinders Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Sectional view (Steering cylinder) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Sectional view (Crab cylinder) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE Cylinders Remove the crab cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install the crab cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Remove the steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install the steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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Cylinders - Exploded view

RAIL14COM0806GA

S. No 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

1

Description Cylinder Collar Washer Pin Grease fitting Lock plate Washer Hexagonal screw Connector Hose Copper washer Hose Banjo bolt

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RAIL14COM0807HA

S. No 1.

2.

2

Description Cylinder Collar 47772910 15/12/2014

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3.

4.

5.

6.

7.

8.

9.

10.

11.

Washer Pin Grease fitting Lock plate Washer Hexagonal screw Connector Hose Hose

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Cylinders - Sectional view (Steering cylinder)

RAIL14COM0512AA

1.

2.

3.

4.

5.

6.

7.

1

Seal Seal Wiper ring O-ring O-ring Ring Ring

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Cylinders - Sectional view (Crab cylinder)

RAIL14COM0513AA

1.

2.

3.

4.

5.

6.

7.

1

Seal Seal Wiper ring O-ring O-ring Ring Ring

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Steering - Cylinders

Cylinders - Remove the crab cylinder 1. Park the machine on a flat level surface.

2. Apply the parking brakes and turn off the engine.

3. Place a suitable drain container with adequate capacity under the crab cylinder (1).

RAIL14COM0462AA

1

RAIL14COM0463AA

2

RAIL14COM0464AA

3

RAIL14COM0465AA

4

4. Remove the lock-plates and attaching hardware (2).

5. Remove the hydraulic hoses (3) and (4). Cover the ports with protective plugs.

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6. Remove the rings and shims. Drive out the cylinder end pin (5).

RAIL14COM0466AA

5

RAIL14COM0467AA

6

7. Remove the rings and shims. Drive out the rod end pin (6).

8. Remove the cylinder (1).

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Cylinders - Install the crab cylinder 1. Position the cylinder (1) in its correct position.

2. Apply grease on the surfaces of the cylinder end pin (5).

3. Secure the cylinder end of the cylinder in place with the pin (5), rings and shims removed earlier.

4. Apply grease on the surfaces of the rod end pin (4).

5. Secure the cylinder end of the cylinder in place with the pin (4), rings and shims removed earlier.

RAIL14COM0467AA

1

RAIL14COM0466AA

2

RAIL14COM0463AA

3

RAIL14COM0464AA

4

6. Install the lock plates with the attaching hardware (2).

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7. Install the hoses (3) and (4) on the cylinder (1).

RAIL14COM0465AA

8. Fill the hydraulic fluid.

9. Start the machine and check for serviceability and leaks.

10. Top up the hydraulic system fluid if necessary.

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Steering - Cylinders

Cylinders - Remove the steering cylinder 1. Park the machine on a flat level surface.

2. Apply the parking brakes and turn off the engine.

3. Place a suitable drain container with adequate capacity under the crab cylinder (1).

RAIL14COM0468AA

1

RAIL14COM0469AA

2

RAIL14COM0470AA

3

RAIL14COM0471AA

4

4. Remove the lock plates and attaching hardware (2).

5. Remove the hydraulic hoses (3) and (4). Cover the ports with protective plugs.

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6. Remove the rings and shims. Drive out the cylinder end pin (5).

RAIL14COM0472AA

5

RAIL14COM0473AA

6

7. Remove the rings and shims. Drive out the rod end pin (6).

8. Remove the cylinder (1).

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Cylinders - Install the steering cylinder 1. Position the cylinder (1) in its correct position.

2. Apply grease on the surfaces of the cylinder end pin (5).

3. Secure the cylinder end of the cylinder in place with the pin (5), rings and shims removed earlier.

4. Apply grease on the surfaces of the rod end pin (6).

5. Secure the cylinder end of the cylinder in place with the pin (6), rings and shims removed earlier.

RAIL14COM0472AA

1

RAIL14COM0473AA

2

RAIL14COM0469AA

3

RAIL14COM0470AA

4

6. Install the lock plates (2) with the attaching hardware.

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7. Install the hoses (3) and (4) on the cylinder (1).

RAIL14COM0471AA

8. Fill the hydraulic fluid.

9. Start the machine and check for serviceability and leaks.

10. Top up the hydraulic system fluid if necessary.

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Steering - Cylinders

Cylinders - Disassemble 1. Lift and securely place the cylinder on a workbench.

NOTICE: Be sure that the cylinder is placed horizontally.

2. Drain hydraulic oil from the cylinder.

3. Unlock the cylinder gland.

SS12K540

1

SS12K541

2

SS12K542

3

SS12K543

4

4. Use a hook wrench to remove the cylinder gland.

NOTE: If necessary gently heat the gland carrier to soften the thread sealant applied during manufacture.

5. Remove the cylinder gland from the cylinder barrel using a plastic hammer.

6. Remove the cylinder rod and cylinder gland.

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7. Remove the piston nut.

8. Remove the piston and gland from the cylinder rod.

SS12K544

9. Check the piston and seals, O-rings, guide and back-up rings of the gland. Replace if necessary.

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Steering - Cylinders

Cylinders - Assemble 1. Install the gland and piston on the cylinder rod.

2. Apply LOCTITE® 577™ to the threads and install the piston nut.

SS12K544

1

SS13G128

2

SS12K545

3

SS12K546

4

3. Install the tool (10) in the cylinder barrel.

4. Insert the piston into the cylinder barrel.

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5. Remove the tool from the cylinder barrel.

SS12K547

5

SS12K548

6

SS12K549

7

6. Install the cylinder gland.

7. Lock the cylinder gland.

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Index Steering - 41 Cylinders - 216 Cylinders - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Cylinders - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Cylinders - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Cylinders - Install the crab cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Cylinders - Install the steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Cylinders - Remove the crab cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Cylinders - Remove the steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Cylinders - Sectional view (Crab cylinder) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Cylinders - Sectional view (Steering cylinder) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 2014 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

CASE CONSTRUCTION policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved.

All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your CASE CONSTRUCTION Dealer.

47772910 15/12/2014 EN

SERVICE MANUAL Wheels DV209C DV210C

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Contents Wheels - 44

[44.160] Compaction drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1

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Wheels - 44 Compaction drums - 160

DV209C DV210C

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Contents Wheels - 44 Compaction drums - 160

FUNCTIONAL DATA Compaction drums Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Compaction drums Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Compaction front drum bearings and carriers Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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Compaction drums - Exploded view

RAIL14COM0812HA

1

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S. No 1.

2.

3.

4.

5.

6.

7.

8.

Description Drive motor Reduction gear box Drive plate Cross member Drum Carrier assembly Vibration motor Side bracket

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RAIL14COM0813HA

S. No 1.

2.

2

Description Drive flange Bolt 47772910 15/12/2014

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Wheels - Compaction drums

S. No 3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20 21 22 23

Description Lock nut Lock washer Bearing Collar Gasket Sealing ring Bolt Washer Drive plate Carrier assembly Nut Vibration isolator Washer Cap screw Clutch Ring Bolt Pulse sensor Motor housing Grease fitting Plug

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RAIL14COM0814HA

S. No 1.

2.

3

Description Snap ring Bearing 47772910 15/12/2014

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Wheels - Compaction drums

S. No 3.

4.

5.

6.

Description Plate Lock washer Lock nut Exciter shaft

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Compaction drums - Remove NOTE: Procedure to remove the rear drum is provided below. The removal process is identical for front and rear drums.

1. Place a suitable drain container with adequate capacity and drain the oil form the drum (1).

NOTE: Approximate drain volume: 15.5 L (4.1 US gal).

RAIL14COM0241AA

1

RAIL14COM0597AA

2

RAIL14COM0555AA

3

2. Support the frame on both the sides. Locks the drum in place against any motion.

Travel motor side 3. Place a suitable drain container with adequate capacity under the travel reduction gearbox.

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4. Remove the bracket (2).

RAIL14COM0557AA

4

RAIL14COM0556AA

5

RAIL14COM0568AA

6

RAIL14COM0569AA

7

5. Remove the hoses (4), (5), (6) and (7) from the travel motor (3).

6. Cover the ports with protective plugs.

7. Support the travel motor side bracket (9) on a suitable lifting device with adequate capacity.

8. Remove the bolts (8) which attach the side bracket (9) on the cross member (10).

9. Remove the bolts (11) which attaches the side bracket (9) on the frame.

10. Remove the bolts (12) which attaches the side bracket (9) on the travel reduction gear.

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11. Remove the side bracket (9).

RAIL14COM0558AA

8

RAIL14COM0598AA

9

12. Remove the clamp (13).

13. Remove the hose (14) from the sprinkler.

14. Remove the cover (15).

15. Disconnect the connector X26.

RAIL14COM0599AA

10

RAIL14COM0626AA

11

16. Support the cross member (10) on a suitable lifting device with adequate capacity.

17. Remove the bolts (8) which attach the vibration motor side bracket (16) on the cross member (10).

18. Remove the cross member (10).

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Vibration motor side 19. Remove the bracket (17).

RAIL14COM0600AA

12

RAIL14COM0601AA

13

RAIL14COM0602AA

14

RAIL14COM0603AA

15

20. Place a suitable drain container with adequate capacity under the vibrations motor.

21. Remove the hoses (18), (19), (20) and (21) from the travel motor (22).

22. Remove the sensor (23).

23. Remove the drain hose (24).

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24. Support the travel motor side bracket (25) on a suitable lifting device with adequate capacity.

25. Remove the bolts (26) which attaches the side bracket (25) on the frame.

RAIL14COM0792AA

16

RAIL14COM0793AA

17

RAIL14COM0604AA

18

26. Remove the bolts (27) which attaches the side bracket (25) on the drum.

27. Remove the side bracket (25).

28. Roll the drum out of the frame.

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Wheels - Compaction drums

Compaction drums - Install vibration motor side 1. Roll the drum (1) to its correct position on the frame.

2. Lift the side bracket (25) with a lifting device of adequate capacity and place in its correct position on the drum.

RAIL14COM0604AA

1

RAIL14COM0793AA

2

RAIL14COM0792AA

3

RAIL14COM0603AA

4

3. Install the side bracket (25) on the drum (1) with the bolts (27).

4. Install the side bracket (25) on the frame with the bolts (26).

5. Install the sensor (23) on the vibrations motor (22).

6. Install the drain hose (24) on the vibrations motor (22).

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7. Install the hoses (18), (19), (20) and (21) on the vibrations motor (22).

RAIL14COM0602AA

5

RAIL14COM0600AA

6

RAIL14COM0626AA

7

RAIL14COM0599AA

8

8. Secure the hoses on the side bracket (25) with the bracket (17) and attaching hardware removed earlier.

9. Lift the cross member (10) with a lifting device of adequate capacity and place in its correct position on the side bracket (25).

10. Install the cross member (10) with the bolts (8).

11. Connect the connectors X26.

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12. Install the cover (15) on the cross member with the bolts removed earlier.

13. Install the hose (14) on the sprinkler.

14. Secure the hose (14) and harness on the side bracket (25) with the clamps (13) and attaching hardware removed earlier.

RAIL14COM0598AA

9

Travel motor side 15. Lift the side bracket (9) with a lifting device of adequate capacity and place in its correct position on the travel reduction gearbox.

RAIL14COM0558AA

10

RAIL14COM0569AA

11

RAIL14COM0568AA

12

16. Install the side bracket (9) on the travel reduction gearbox with the bolts (12) removed earlier.

17. Install the side bracket (9) on the frame with the bolts (11) removed earlier.

18. Install the side bracket (9) on the cross member (10) with the bolts (8) removed earlier.

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19. Connect the hoses (4), (5), (6) and (7) on the travel motor (3).

RAIL14COM0556AA

13

RAIL14COM0557AA

14

20. Secure the hoses on the side bracket (9) with the bracket (2) and attaching hardware removed earlier.

21. Fill the hydraulic system.

22. Start the machine and check for serviceability and leaks.

23. Top-up the hydraulic system if necessary.

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Compaction drums - Disassemble Vibration motor side 1. Lift with a suitable lifting device of adequate capacity and position the drum (1) on vertically with the travel motor side on the ground

RAIL14COM0605AA

1

RAIL14COM0606AA

2

RAIL14COM0607AA

3

RAIL14COM0608AA

4

2. Remove the bolts (2).

3. Remove the vibration motor (3).

4. Remove the plugs (4) and bolts (5) from the bearing cover (6).

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5. Use two bolts (A) to push the bearing cover (6) out of the drum.

RAIL14COM0609AA

5

RAIL14COM0610AA

6

RAIL14COM0611AA

7

RAIL14COM0612AA

8

6. Lift and remove the suspension assembly (B) form the drum with a suitable lifting device of adequate capacity.

7. Check the O-ring (7) for condition, replace if necessary.

8. Remove the plugs (8) and bolts (9) from the bearing cover.

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Wheels - Compaction drums

9. Use two bolts (C) to push the bearing cover (6) out of the suspension assembly (B).

RAIL14COM0613AA

9

10. Lift and remove the suspension assembly (B) form the bearing cover (6) with a suitable lifting device of adequate capacity.

RAIL14COM0614AA

10

RAIL14COM0615AA

11

RAIL14COM0616AA

12

11. Remove the snap ring (10).

12. Use the bolts (D) to drive out the bearing (11).

NOTICE: Turn the bolts evenly.

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Wheels - Compaction drums

13. Install the lifting lug (12) on the vibrator shaft (13).

14. Lift the vibrator shaft (13) out of the drum with a suitable lifting device of adequate capacity.

RAIL14COM0617AA

13

RAIL14COM0606AA

14

RAIL14COM0618AA

15

RAIL14COM0619AA

16

Travel motor side 15. Lift with a suitable lifting device of adequate capacity and position the drum (1) on vertically with the vibration motor side on the ground

16. Remove the bolts (14).

17. Install the lifting lug (15) on the reduction gearbox (16).

18. Lift and remove the reduction gearbox along with the carrier using a suitable lifting device of adequate capacity.

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Wheels - Compaction drums

19. Remove the plugs (17) and bolts (18) from the bearing cover (19).

RAIL14COM0631AA

17

RAIL14COM0632AA

18

RAIL14COM0633AA

19

RAIL14COM0615AA

20

20. Use the bolts (E) to push the bearing cover (19) out of the drum.

21. Install the lifting lugs (20) on the bearing cover (19).

22. Lift the bearing cover (19) with a suitable lifting device of adequate capacity.

23. Check the O-ring (21) for condition, replace if necessary.

24. Remove the snap ring (22).

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Wheels - Compaction drums

25. Remove the bolts (23).

26. Remove the cover (24).

RAIL14COM0634AA

21

RAIL14COM0635AA

22

RAIL14COM0636AA

23

RAIL14COM0637AA

24

27. Use the bolts (F) to drive out the bearing (25).

NOTICE: Turn the bolts evenly.

Vibrator shaft Travel motor side 28. Remove the snap ring (26).

29. Remove the nut (27).

30. Remove the bearing (28) with a puller.

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Wheels - Compaction drums

Vibration motor side 31. Remove the bolt (30) from the gear (29).

RAIL14COM0638AA

25

RAIL14COM0639AA

26

RAIL14COM0640AA

27

RAIL14COM0641AA

28

32. Heat the coupling to 400 °C (752 °F) and remove from the shaft.

33. Remove the snap ring (31).

34. Remove the nut (32).

35. Remove the bearing (33) with a puller.

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Wheels - Compaction drums

Compaction drums - Assemble Vibrator shaft Vibration motor side 1. Heat the bearing (31) to 100 °C (212 °F) and install on the shaft.

2. Secure the bearing (31) with the nut (32) and snap ring (31).

RAIL14COM0640AA

1

RAIL14COM0638AA

2

RAIL14COM0636AA

3

3. Heat the gear (29) to 400 °C (752 °F) and install on the shaft.

4. Apply LOCTITE® 262™ on the threads of the bolt (30).

5. Secure the gear (29) on the shaft with the bolt (30).

Torque the bolts to 10 N·m (7 lb ft).

Travel motor side 6. Heat the bearing (28) to 100 °C (212 °F) and install on the shaft.

7. Secure the bearing (28) with the nut (27) and snap ring (26).

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Wheels - Compaction drums

Bearings Travel motor side 8. Install the bearing (25) on the cover assembly.

RAIL14COM0635AA

4

RAIL14COM0615AA

5

RAIL14COM0634AA

6

RAIL14COM0633AA

7

9. Secure the bearing (25) with the snap ring (22).

10. Apply Red RTV Silicone sealant on the contact surfaces of the cover (24).

11. Install the cover (24) with the bolts (23).

12. Lift the bearing cover assembly (19) with suitable lifting lugs (20) and lifting device and place in its correct position on the drum.

NOTICE: Make sure that the O-ring (21) is installed.

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Wheels - Compaction drums

13. Apply LOCTITE® 262™ on the threads of the bolt (18) and plugs (17).

14. Install the cover assembly (19) with the bolts (18).

15. Install the plugs (17).

RAIL14COM0631AA

8

RAIL14COM0619AA

9

16. Lift the reduction gearbox (16) along with the carrier assembly with suitable lifting lugs (15) and lifting device and place in its correct position on the drum.

17. Install the bolts (14).

RAIL14COM0618AA

10

RAIL14COM0606AA

11

Vibration motor side 18. Lift with a suitable lifting device of adequate capacity and position the drum (1) on vertically with the travel motor side on the ground.

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Wheels - Compaction drums

19. Install the lifting lug (12) on the vibrator shaft (13).

20. Lift the pre-assembled vibrator shaft (13) with a suitable lifting device of adequate capacity and place it in its correct position in the drum.

RAIL14COM0617AA

12

RAIL14COM0616AA

13

RAIL14COM0615AA

14

RAIL14COM0612AA

15

21. Install the bearing (11) on the cover assembly (6).

22. Secure the bearing (11) with the snap ring (10).

23. Apply LOCTITE® 262™ on the threads of the bolt (8) and plugs (9).

24. Install the cover assembly (6) on the flange assembly (B) with the bolts (8).

25. Install the plugs (9).

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26. Lift the flange assembly (B) with suitable lifting device of adequate capacity and place it in its correct position in the drum.

NOTICE: Make sure that the O-ring (7) is installed.

RAIL14COM0610AA

16

RAIL14COM0608AA

17

RAIL14COM0607AA

18

27. Apply LOCTITE® 262™ on the threads of the bolt (5) and plugs (4).

28. Install the flange assembly (B) on the drum with the bolts (5).

29. Install the plugs (4).

30. Install the vibration motor (3) with the bolts (2).

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Wheels - Compaction drums

Compaction front drum bearings and carriers - Remove 1. Place a suitable drain container with adequate capacity under the drain ports.

2. Remove the drain plug and drain the oil from the drum (1).

RAIL14COM0241AA

1

RAIL14COM0598AA

2

RAIL14COM0600AA

3

RAIL14COM0578AA

4

3. Remove the clamp (2).

4. Remove the bracket (3).

5. Place a suitable drain container with adequate capacity under the vibrations motor.

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6. Remove the hoses (4), (5), (6) and (7) from the vibrations motor.

RAIL14COM0602AA

5

RAIL14COM0603AA

6

RAIL14COM0792AA

7

RAIL14COM0793AA

8

7. Remove the drain hose (8) and sensor (9) from the vibration motor.

8. Support the side bracket (10) with a suitable lifting device of adequate capacity.

9. Remove the bolts (11) which attach the side bracket (10) on the cross member.

10. Remove the bolts (12) which attach the side bracket (10) on the frame.

11. Remove the bolts (13) from the side bracket (10).

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Wheels - Compaction drums

12. Remove the side bracket (10) from the machine.

RAIL14COM0604AA

9

13. Remove the bolts (14) which secures the pump (15) on the drum.

14. Remove the pump (15).

RAIL14COM0607AA

10

RAIL14COM0642AA

11

RAIL14COM0608AA

12

15. Support the flange assembly (16) with a suitable lifting device of adequate capacity.

16. Remove the bolts (18) which attaches the cover (17) on the drum.

17. Remove the plugs (19).

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18. Use the bolts (A) to force the cover out of the drum.

19. Remove the flange assembly (16) from the machine with the lifting device.

RAIL14COM0609AA

13

RAIL14COM0643AA

14

RAIL14COM0644AA

15

RAIL14COM0645AA

16

20. Make identification marks on the spacer (20) and flange assembly (16) to enable easy installation.

21. Remove the bolts (21) which attaches the spacer (20) on the flange assembly.

22. Use the bolts (B) to force the spacer (20) out of the flange assembly.

23. Release the tab of the lock washer (22) from the nut.

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Wheels - Compaction drums

24. Remove the nut (23) and lock washer (22).

RAIL14COM0646AA

17

RAIL14COM0647AA

18

RAIL14COM0648AA

19

RAIL14COM0649AA

20

25. Support the bearing cover (18) as shown.

26. Press out the bearing (24).

27. Use the bolts (C) to drive out the inner rings of the bearings.

NOTICE: Tighten the bolts evenly.

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Index Wheels - 44 Compaction drums - 160 Compaction drums - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Compaction drums - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Compaction drums - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Compaction drums - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Compaction drums - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Compaction front drum bearings and carriers - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 2014 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

CASE CONSTRUCTION policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved.

All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your CASE CONSTRUCTION Dealer.

47772910 15/12/2014 EN

SERVICE MANUAL Cab climate control DV209C DV210C

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50

Contents Cab climate control - 50

[50.100] Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1

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Cab climate control - 50 Heating - 100

DV209C DV210C

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Contents Cab climate control - 50 Heating - 100

SERVICE Heater core Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Heater control valve Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Cab climate control - Heating

Heater core - Remove 1. Place a suitable drain collector under the frame.

2. Drain the coolant.

NOTE: Approximate drain volume: 23 L (6.1 US gal).

RAIL14COM0514AA

1

RAIL14COM0684AA

2

RAIL14COM0686AA

3

RAIL14COM0687AA

4

3. Remove the bolts (1).

4. Remove the cover (2).

5. Disconnect the heater connector (3).

6. Remove the hoses (4) and (5) from the heater core (6).

7. Remove the bolts (7) from the heater core (6).

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Cab climate control - Heating

8. Remove the heater core (6).

RAIL14COM0688AA

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5

Cab climate control - Heating

Heater core - Install 1. Position the heater core (6) in its correct position.

RAIL14COM0688AA

1

RAIL14COM0687AA

2

RAIL14COM0686AA

3

RAIL14COM0684AA

4

2. Install the heater core (6) in place with the bolts (7).

3. Install the hoses (4) and (5) on the heater core (6).

4. Connect the connector (3).

5. Instal the cover (2) with the bolts (1).

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6. Install the drain plug and fill the coolant.

7. Start the engine and check for serviceability and leaks.

8. Top up the coolant as necessary.

RAIL14COM0514AA

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5

Cab climate control - Heating

Heater control valve - Remove 1. Place a suitable drain collector under the frame.

2. Drain the coolant.

NOTE: Approximate drain volume: 23 L (6.1 US gal).

RAIL14COM0514AA

1

RAIL14COM0684AA

2

RAIL14COM0685AA

3

3. Remove the bolts (1).

4. Remove the cover (2).

5. Remove the clamps (3).

6. Remove the heater control valve (4)

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Heater control valve - Install 1. Install the heater control valve (4) on the hoses with the clamps (3).

RAIL14COM0685AA

1

RAIL14COM0684AA

2

RAIL14COM0514AA

3

2. Install the cover (2) with the bolts (1).

3. Install the drain plug and refill the engine coolant.

4. Start the engine and check for serviceability and leaks.

5. Top up the coolant if necessary.

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Index Cab climate control - 50 Heating - 100 Heater control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Heater control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Heater core - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Heater core - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 2014 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

CASE CONSTRUCTION policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved.

All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your CASE CONSTRUCTION Dealer.

47772910 15/12/2014 EN

SERVICE MANUAL Electrical systems DV209C DV210C

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55

Contents Electrical systems - 55

[55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system. . . . . . . . . . . . . . . . . . . 55.5 [55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6

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Electrical systems - 55 Harnesses and connectors - 100

DV209C DV210C

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Contents Electrical systems - 55 Harnesses and connectors - 100

FUNCTIONAL DATA Wiring harnesses Electrical schematic sheet 02 SH-2 STARTING CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Electrical schematic sheet 03 SH-3 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Electrical schematic sheet 04 SH-4 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Electrical schematic sheet 05 SH-5 CAN NETWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Electrical schematic sheet 06 SH-6 ELECTROHYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Electrical schematic sheet 07 SH-7 ELECTROHYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Electrical schematic sheet 08 SH-8 ELECTROHYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Electrical schematic sheet 09 SH-9 ELECTROHYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Electrical schematic sheet 10 SH-10 ELECTROHYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Electrical schematic sheet 11 SH-11 DRIVER GESSMANN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Electrical schematic sheet 12 SH-12 DRIVER GESSMANN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Electrical schematic sheet 13 SH-13 LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Electrical schematic sheet 14 SH-14 LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Electrical schematic sheet 15 SH-15 LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Electrical schematic sheet 16 SH-16 LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Electrical schematic sheet 17 SH-17 LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Electrical schematic sheet 18 SH-18 CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Electrical schematic sheet 19 SH-19 CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Electrical schematic sheet 20 SH-20 GROUNDING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Electrical schematic sheet 21 SH-21 GROUNDING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Electrical schematic sheet 21 SH-21 GROUNDING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Fuse and relay box Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 02 SH-2 STARTING CHARGING

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SHT_2

1

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Wiring harnesses - Electrical schematic sheet 03 SH-3 ENGINE

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SHT_3

1

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Wiring harnesses - Electrical schematic sheet 04 SH-4 ENGINE

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SHT_4

1

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Wiring harnesses - Electrical schematic sheet 05 SH-5 CAN NETWORK

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SHT_5

1

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 06 SH-6 ELECTROHYDRAULIC

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SHT_6

1

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 07 SH-7 ELECTROHYDRAULIC

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SHT_7

1

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 08 SH-8 ELECTROHYDRAULIC

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SHT_8

1

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 09 SH-9 ELECTROHYDRAULIC

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Electrical systems - Harnesses and connectors

SHT_9

1

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 10 SH-10 ELECTROHYDRAULIC

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SHT_10

1

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Wiring harnesses - Electrical schematic sheet 11 SH-11 DRIVER GESSMANN

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SHT_11

1

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Wiring harnesses - Electrical schematic sheet 12 SH-12 DRIVER GESSMANN

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SHT_12

1

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Wiring harnesses - Electrical schematic sheet 13 SH-13 LIGHTING SYSTEM

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SHT_13

1

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Wiring harnesses - Electrical schematic sheet 14 SH-14 LIGHTING SYSTEM

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SHT_14

1

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Wiring harnesses - Electrical schematic sheet 15 SH-15 LIGHTING SYSTEM

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1

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Wiring harnesses - Electrical schematic sheet 16 SH-16 LIGHTING SYSTEM

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1

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Wiring harnesses - Electrical schematic sheet 17 SH-17 LIGHTING SYSTEM

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SHT_17

1

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Wiring harnesses - Electrical schematic sheet 18 SH-18 CAB

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1

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Wiring harnesses - Electrical schematic sheet 19 SH-19 CAB

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1

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Wiring harnesses - Electrical schematic sheet 20 SH-20 GROUNDING SYSTEM

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1

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Wiring harnesses - Electrical schematic sheet 21 SH-21 GROUNDING SYSTEM Type Ground Ground

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Component GND-001 GND-002

Connector / Link GND-001 GND-002

Description ENGINE FRAME MACHINE FRAME

Electrical systems - Harnesses and connectors

SHT_21

1

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Wiring harnesses - Electrical schematic sheet 21 SH-21 GROUNDING SYSTEM Type Ground Ground

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Component GND-001 GND-002

Connector / Link GND-001 GND-002

Description ENGINE FRAME MACHINE FRAME

Electrical systems - Harnesses and connectors

SHT_21

1

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Electrical systems - Harnesses and connectors

Fuse and relay box - Identification Cab fuse and relay 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

1

RAIL14COM0222AA

2

Engine compartment fuses 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

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Index Electrical systems - 55 Harnesses and connectors - 100 Wiring harnesses - Electrical schematic sheet 03 SH-3 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Wiring harnesses - Electrical schematic sheet 04 SH-4 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Wiring harnesses - Electrical schematic sheet 05 SH-5 CAN NETWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Wiring harnesses - Electrical schematic sheet 06 SH-6 ELECTROHYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Wiring harnesses - Electrical schematic sheet 07 SH-7 ELECTROHYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Wiring harnesses - Electrical schematic sheet 08 SH-8 ELECTROHYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Wiring harnesses - Electrical schematic sheet 09 SH-9 ELECTROHYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Wiring harnesses - Electrical schematic sheet 10 SH-10 ELECTROHYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Wiring harnesses - Electrical schematic sheet 11 SH-11 DRIVER GESSMANN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Wiring harnesses - Electrical schematic sheet 12 SH-12 DRIVER GESSMANN . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Wiring harnesses - Electrical schematic sheet 13 SH-13 LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Wiring harnesses - Electrical schematic sheet 14 SH-14 LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Wiring harnesses - Electrical schematic sheet 15 SH-15 LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Wiring harnesses - Electrical schematic sheet 16 SH-16 LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Wiring harnesses - Electrical schematic sheet 17 SH-17 LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Wiring harnesses - Electrical schematic sheet 18 SH-18 CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Wiring harnesses - Electrical schematic sheet 19 SH-19 CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Wiring harnesses - Electrical schematic sheet 20 SH-20 GROUNDING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Wiring harnesses - Electrical schematic sheet 21 SH-21 GROUNDING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Wiring harnesses - Electrical schematic sheet 21 SH-21 GROUNDING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Fuse and relay box - Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Wiring harnesses - Electrical schematic sheet 02 SH-2 STARTING CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - 55 Alternator - 301

DV209C DV210C

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Contents Electrical systems - 55 Alternator - 301

TECHNICAL DATA Alternator General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - Alternator

Alternator - General specification Technical specifications Voltage Current Weight

12 V 80 A 7.7 kg (17 lb)

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Index Electrical systems - 55 Alternator - 301 Alternator - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Battery - 302

DV209C DV210C

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Contents Electrical systems - 55 Battery - 302

TECHNICAL DATA Battery General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - Battery

Battery - General specification The machine is equipped with two batteries connected in series. The technical specifications of the batteries are as follows: Voltage Capacity

Battery Specification 12 V 55 A·h

RAIL14COM0782AA

Connection and disconnection When disconnecting, always disconnect the negative terminal first.

When connecting the battery, always connect the positive terminal first.

Apply PETROLEUM JELLY on the terminals to avoid corrosion.

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1

Index Electrical systems - 55 Battery - 302 Battery - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Cab controls - 512

DV209C DV210C

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Contents Electrical systems - 55 Cab controls - 512

SERVICE Cab controls Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Electrical systems - Cab controls

Cab controls - Remove Right-hand side arm rest Travel control lever 1. Remove the cover (1).

RAIL14COM0773AA

1

RAIL14COM0774AA

2

RAIL14COM0775AA

3

2. Disconnect the connectors (X1), (X2), (X3) and (X4).

3. Remove the bolts (2).

4. Remove the travel control lever (3).

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Electrical systems - Cab controls

Switches 5. Remove the cover (1).

RAIL14COM0773AA

4

RAIL14COM0776AA

5

RAIL14COM0778AA

6

6. Remove the switch receptacles (4).

7. Remove the nut (5).

8. Remove the switch (6).

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Electrical systems - Cab controls

Left-hand side arm rest Switches 9. Remove the cover (7).

RAIL14COM0779AA

7

RAIL14COM0780AA

8

RAIL14COM0778AA

9

10. Remove the switch receptacles (8).

11. Remove the nut (9).

12. Remove the switch (10).

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Electrical systems - Cab controls

Cab controls - Install right-hand side arm rest travel control lever 1. Install the travel control lever (3) on the arm rest with the bolts (2).

RAIL14COM0775AA

1

RAIL14COM0774AA

2

RAIL14COM0773AA

3

2. Connect the connectors (X1), (X2), (X3) and (X4).

3. Install the cover (1).

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Electrical systems - Cab controls

Switches 4. Install the switch (6) on the arm rest with the nut (5).

RAIL14COM0778AA

4

RAIL14COM0776AA

5

RAIL14COM0773AA

6

5. Install the receptacle (4) on the arm rest.

6. Install the cover (1).

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Electrical systems - Cab controls

Left-hand side arm rest Switches 7. Install the switch (9) on the arm rest with the nut (10).

RAIL14COM0778AA

7

RAIL14COM0780AA

8

RAIL14COM0779AA

9

8. Install the receptacle (8) on the arm rest.

9. Install the cover (7).

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Index Electrical systems - 55 Cab controls - 512 Cab controls - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Cab controls - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Heating, Ventilation, and Air-Conditioning (HVAC) control system 050

DV209C DV210C

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Contents Electrical systems - 55 Heating, Ventilation, and Air-Conditioning (HVAC) control system - 050

SERVICE Blower Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system

Blower - Remove 1. Place a suitable drain collector under the frame.

2. Drain the coolant.

NOTE: Approximate. drain volume: 23 L (6.1 US gal).

RAIL14COM0514AA

1

RAIL14COM0684AA

2

RAIL14COM0686AA

3

RAIL14COM0687AA

4

3. Remove the bolts (1).

4. Remove the cover (2).

5. Disconnect the heater connector (3).

6. Remove the hoses (4) and (5) from the heater core (6).

7. Remove the bolts (7) from the heater core (6).

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Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system

8. Remove the heater core (6).

RAIL14COM0688AA

5

RAIL14COM0690AA

6

RAIL14COM0691AA

7

RAIL14COM0692AA

8

9. Identify and mark the wires and disconnect them.

10. Remove the bolts (8) which secures the blower unit (9).

11. Remove the blower unit (9).

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Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system

Blower - Install 1. Install the blower unit (9) with the bolts (8).

RAIL14COM0692AA

1

RAIL14COM0691AA

2

RAIL14COM0690AA

3

RAIL14COM0688AA

4

2. Connect the wires as identified during removal.

3. Position the heater core (6) in its correct position.

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Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system

4. Install the heater core (6) in place with the bolts (7).

RAIL14COM0687AA

5

RAIL14COM0686AA

6

RAIL14COM0684AA

7

RAIL14COM0514AA

8

5. Install the hoses (4) and (5) on the heater core (6).

6. Connect the connector (3).

7. Instal the cover (2) with the bolts (1).

8. Install the drain plug and fill the coolant.

9. Start the engine and check for serviceability and leaks.

10. Top up the coolant as necessary.

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Index Electrical systems - 55 Heating, Ventilation, and Air-Conditioning (HVAC) control system - 050 Blower - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Blower - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Warning indicators, alarms, and instruments - 408

DV209C DV210C

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Contents Electrical systems - 55 Warning indicators, alarms, and instruments - 408

SERVICE Operator presence switch Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Electrical systems - Warning indicators, alarms, and instruments

Operator presence switch - Remove 1. Remove the bolts (1) from the seat base (2).

RAIL14COM0767AA

1

RAIL14COM0768AA

2

RAIL14COM0769AA

3

RAIL14COM0770AA

4

2. Lift the seat base (2).

3. Drill out the rivets (3) which attaches the operator presence switch (8) on the seat frame.

4. Remove the covers (4) and (5).

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Electrical systems - Warning indicators, alarms, and instruments

5. Remove the bolts (6) which attaches the seat (7).

RAIL14COM0771AA

5

RAIL14COM0772AA

6

6. Lift the seat (7).

7. Disconnect the connector (X2).

8. Remove the operator presence switch (8) and wiring.

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Electrical systems - Warning indicators, alarms, and instruments

Operator presence switch - Install 1. Connect the connector (X2) and route the wiring to the seat (7).

RAIL14COM0772AA

1

RAIL14COM0769AA

2

RAIL14COM0771AA

3

RAIL14COM0770AA

4

2. Install the operator presence switch (8) on the seat frame with the rivets (3).

3. Install the seat (7) with the bolts (6).

4. Install the covers (4) and (5).

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Electrical systems - Warning indicators, alarms, and instruments

5. Install the seat base (2) with the bolts (1).

RAIL14COM0767AA

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5

Index Electrical systems - 55 Warning indicators, alarms, and instruments - 408 Operator presence switch - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Operator presence switch - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 2014 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

CASE CONSTRUCTION policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved.

All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your CASE CONSTRUCTION Dealer.

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SERVICE MANUAL Platform, cab, bodywork, and decals DV209C DV210C

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90

Contents Platform, cab, bodywork, and decals - 90

[90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1

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90

Platform, cab, bodywork, and decals - 90 Cab - 150

DV209C DV210C

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Contents Platform, cab, bodywork, and decals - 90 Cab - 150

SERVICE Cab Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Cab and platform Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Cab suspension Replace the vibration cab isolators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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Platform, cab, bodywork, and decals - Cab

Cab - Remove 1. Place a suitable drain collector under the frame.

2. Remove the drain plug and drain the coolant.

RAIL14COM0514AA

1

RAIL14COM0693AA

2

RAIL14COM0694AA

3

RAIL14COM0695AA

4

3. Remove the bolts (1).

4. Remove the cover (2).

5. Remove the connector from the Service Switch (S40).

6. Remove the cover (2).

7. Remove the connector (A).

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Platform, cab, bodywork, and decals - Cab

8. Remove the plates (3) on both the sides.

RAIL14COM0696AA

5

RAIL14COM0697AA

6

RAIL14COM0698AA

7

9. Remove the cover (4).

10. Remove the heating hoses (5) and (6).

11. Remove the bolts (7).

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Platform, cab, bodywork, and decals - Cab

12. Remove the bolts on the cab roof and install the lifting lugs (B).

13. Secure the cab with a suitable lifting device of adequate capacity.

NOTICE: Cab assembly weighs 540 kg (1190 lb).

RAIL14COM0699AA

8

RAIL14COM0700AA

9

14. Remove the bolts (8) which attaches the left side of cab on the frame.

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RAIL14COM0701AA

10

RAIL14COM0702AA

11

Platform, cab, bodywork, and decals - Cab

15. Remove the bolts (9) which attaches the left side of cab on the frame.

16. Remove the cab using the lifting device.

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RAIL14COM0703AA

12

RAIL14COM0704AA

13

Platform, cab, bodywork, and decals - Cab

Cab - Install 1. Lift the cab with suitable lifting device of adequate capacity and place it on the machine.

NOTICE: Cab assembly weighs 540 kg (1190 lb). Use a suitable lifting device with adequate capacity.

RAIL14COM0699AA

1

RAIL14COM0700AA

2

RAIL14COM0704AA

3

RAIL14COM0703AA

4

2. Install the left side of the cab on the platform with bolts (9) and (11).

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Platform, cab, bodywork, and decals - Cab

3. Install the right side of the cab on the platform with bolts (8) and (9).

RAIL14COM0702AA

5

RAIL14COM0701AA

6

RAIL14COM0700AA

7

RAIL14COM0699AA

8

4. Remove the lifting device from the cab.

5. Install the bolts removed earlier.

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Platform, cab, bodywork, and decals - Cab

6. Install the bolts (7).

7. Connect the heating hoses (5) and (6).

RAIL14COM0698AA

9

8. Install the cover (4).

RAIL14COM0697AA

10

RAIL14COM0696AA

11

RAIL14COM0695AA

12

9. Install the plates (3) on both the sides.

10. Connect the connector (A).

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Platform, cab, bodywork, and decals - Cab

11. Install the connector from the Service Switch (S40).

RAIL14COM0694AA

13

RAIL14COM0693AA

14

RAIL14COM0514AA

15

12. Install the cover (2) with the bolts (1)

13. Install the coolant drain plug and refill the coolant.

14. Start the machine and check for serviceability and leaks.

15. Top up the coolant if necessary.

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Platform, cab, bodywork, and decals - Cab

Cab and platform - Remove 1. Place a suitable drain collector under the frame.

2. Remove the drain plug and drain the coolant.

NOTE: Approximate drain volume 23 L (6.1 US gal).

RAIL14COM0514AA

1

RAIL14COM0449AA

2

RAIL14COM0706AA

3

RAIL14COM0707AA

4

3. Place a suitable drain collector under the hydraulic oil drain plug.

4. Remove the drain plug and drain the hydraulic oil.

NOTE: Approximate drain volume 60 L (16 US gal).

5. Refer to Cab - Remove (90.150) and remove the cab.

6. Remove the cover (1).

7. Disconnect the connector (X11).

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Platform, cab, bodywork, and decals - Cab

8. Disconnect the connector (A) and (B).

RAIL14COM0708AA

5

RAIL14COM0709AA

6

RAIL14COM0710AA

7

RAIL14COM0711AA

8

9. Disconnect the connector (C).

10. Remove the relay (K11) .

11. Disconnect the terminals from wires 001 and 002.

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Platform, cab, bodywork, and decals - Cab

12. Remove the cover (2).

RAIL14COM0712AA

9

13. Remove the bolts (3).

14. Remove the bracket (4).

RAIL14COM0713AA

10

RAIL14COM0714AA

11

RAIL14COM0715AA

12

15. Remove the end of the cable drag chain (5) from the bracket.

16. Remove the bolts (6).

17. Remove the bracket (7).

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Platform, cab, bodywork, and decals - Cab

18. Remove the clamps (8).

19. Disconnect the hose (9) on the fitting (10).

RAIL14COM0716AA

13

RAIL14COM0718AA

14

RAIL14COM0719AA

15

RAIL14COM0721AA

16

20. Disconnect the hoses (11) and (12) from the fittings under the platform.

21. Remove the hoses (13) and (14) from the valve (15).

22. Disconnect the hose (16).

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Platform, cab, bodywork, and decals - Cab

23. Remove the bolts (17) and (18).

RAIL14COM0722AA

17

RAIL14COM0723AA

18

RAIL14COM0725AA

19

24. Install the mounting lugs (D) on the plat form.

25. Support the platform on a suitable lifting device of adequate capacity.

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Platform, cab, bodywork, and decals - Cab

26. Lift the platform slightly above the frame and remove the plate (19).

RAIL14COM0727AA

20

RAIL14COM0728AA

21

RAIL14COM0729AA

22

RAIL14COM0730AA

23

27. Disconnect the connectors (E) and (F) from the

28. Lift and remove the platform.

NOTICE: Make sure that the hoses are not damaged.

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Platform, cab, bodywork, and decals - Cab

Cab and platform - Install 1. Attach the lifting lugs (D) on the platform. Lift the platform with a suitable lifting device of adequate capacity.

NOTICE: Approximate weight of the platform: 310 kg (683 lb).

RAIL14COM0731AA

1

RAIL14COM0728AA

2

RAIL14COM0729AA

3

RAIL14COM0730AA

4

2. Install plate (19) on the platform.

3. Connect the connectors (E) and (F) on the platform.

4. Lift the platform above the frame and route the hoses in their correct position.

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Platform, cab, bodywork, and decals - Cab

5. Place the platform in its correct position on the frame.

RAIL14COM0724AA

5

RAIL14COM0725AA

6

RAIL14COM0722AA

7

RAIL14COM0723AA

8

6. Remove the lifting lugs (D)

7. Install the platform on the frame with the bolts (17) and (18).

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Platform, cab, bodywork, and decals - Cab

8. Install the hose (16).

RAIL14COM0721AA

9

9. Install the hoses (13) and (14) on the valve (15).

RAIL14COM0719AA

10

RAIL14COM0718AA

11

RAIL14COM0716AA

12

10. Install the hoses (11) and (12) on the fittings under the platform.

11. Install the hose (9) on the fitting (10) with the clamp (8).

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Platform, cab, bodywork, and decals - Cab

12. Install the bracket (7) with the bolts (6).

RAIL14COM0715AA

13

RAIL14COM0714AA

14

RAIL14COM0713AA

15

RAIL14COM0712AA

16

13. Secure the hoses (H) with the cable drag chain (5).

14. Install the bracket (4) with the bolts (3).

15. Install the cover (2).

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Platform, cab, bodywork, and decals - Cab

16. Connect the terminals from wires 001 and 002.

RAIL14COM0711AA

17

RAIL14COM0710AA

18

RAIL14COM0709AA

19

RAIL14COM0708AA

20

17. Install the relay (K11).

18. Connect the connector (C).

19. Connect the connector (A) and (B).

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Platform, cab, bodywork, and decals - Cab

20. Connect the connector (X11).

RAIL14COM0707AA

21

RAIL14COM0706AA

22

RAIL14COM0449AA

23

RAIL14COM0514AA

24

21. Install the cover (1).

22. Refer to Cab - Install (90.150) and remove the cab.

23. Install the drain plug and refill the hydraulic oil.

24. Install the drain plug and refill the engine coolant.

25. Start the machine and check for serviceability and leaks.

26. Top-up the hydraulic oil and coolant if necessary.

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Platform, cab, bodywork, and decals - Cab

Cab suspension - Replace the vibration cab isolators Removal 1. Refer to Cab - Remove (90.150) and remove the cab.

2. Place a suitable drain collector under the frame.

3. Remove the drain plug and drain the coolant.

NOTE: Approximate drain volume: 23 L (6.1 US gal).

RAIL14COM0514AA

1

RAIL14COM0706AA

2

RAIL14COM0707AA

3

RAIL14COM0708AA

4

4. Remove the cover (1).

5. Disconnect the connector (X11).

6. Disconnect the connectors (A) and (B).

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Platform, cab, bodywork, and decals - Cab

7. Disconnect the connector (C).

RAIL14COM0709AA

5

RAIL14COM0710AA

6

RAIL14COM0711AA

7

RAIL14COM0712AA

8

8. Remove the relay (K11).

9. Disconnect the wires 001 and 002 from the relay holder.

10. Remove the cover (2).

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Platform, cab, bodywork, and decals - Cab

11. Remove the bolts (3).

12. Remove the bracket (4).

RAIL14COM0713AA

9

13. Remove the end of the cable drag chain (5) from the bracket.

RAIL14COM0714AA

10

RAIL14COM0715AA

11

14. Remove the bolts (7) and bracket (6).

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Platform, cab, bodywork, and decals - Cab

15. Remove the bolts (8) and (9).

RAIL14COM0722AA

12

RAIL14COM0723AA

13

RAIL14COM0725AA

14

RAIL14COM0727AA

15

16. Install the mounting lugs (D) on the platform.

17. Support the platform on a suitable lifting device of adequate capacity.

18. Lift the platform slightly above the frame.

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Platform, cab, bodywork, and decals - Cab

19. Remove the bolts (10) and vibration isolators (11) from the front of the machine.

RAIL14COM0732AA

16

RAIL14COM0733AA

17

RAIL14COM0734AA

18

RAIL14COM0735AA

19

20. Remove the bolts (10) and vibration isolators (11) from the rear of the machine.

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Platform, cab, bodywork, and decals - Cab

Installation 21. Install the vibration isolators (11) with the bolts on the front side of the frame.

RAIL14COM0732AA

20

RAIL14COM0733AA

21

RAIL14COM0734AA

22

RAIL14COM0735AA

23

22. Install the vibration isolators (11) with the bolts on the rear side of the frame.

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Platform, cab, bodywork, and decals - Cab

23. Place the frame in its correct position.

RAIL14COM0727AA

24

RAIL14COM0725AA

25

RAIL14COM0722AA

26

RAIL14COM0723AA

27

24. Remove the lifting lugs (D) from the frame.

25. Install the platform on the frame with the bolts (8) and (9).

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Platform, cab, bodywork, and decals - Cab

26. Install the bracket (6) with the bolts (7).

RAIL14COM0715AA

28

RAIL14COM0714AA

29

RAIL14COM0713AA

30

RAIL14COM0712AA

31

27. Secure the hoses (H) with the cable drag chain (5).

28. Install the bracket (4) with the bolts (3).

29. Install the cover (2).

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Platform, cab, bodywork, and decals - Cab

30. Connect the terminals of the wires 001 and 002.

RAIL14COM0711AA

32

RAIL14COM0710AA

33

RAIL14COM0709AA

34

RAIL14COM0708AA

35

31. Install the relay (K11).

32. Connect the connector (C).

33. Connect the connectors (A) and (B).

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Platform, cab, bodywork, and decals - Cab

34. Connect the connector (X11).

RAIL14COM0707AA

36

RAIL14COM0706AA

37

RAIL14COM0514AA

38

35. Install the cover (1).

36. Install the drain plug and fill the coolant.

37. Refer to Cab - Install (90.150) and install the cab.

38. Start the machine and check for serviceability and leaks.

39. Top-up the coolant if required.

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Index Platform, cab, bodywork, and decals - 90 Cab - 150 Cab - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Cab - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Cab and platform - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Cab and platform - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Cab suspension - Replace the vibration cab isolators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 2014 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

CASE CONSTRUCTION policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved.

All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your CASE CONSTRUCTION Dealer.

47772910 15/12/2014 EN

47772910 15/12/2014 EN

CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404 SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 2014 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

CASE CONSTRUCTION policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved.

All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your CASE CONSTRUCTION Dealer.

47772910 15/12/2014 EN