Case DV213 Tier 3 Vibratory Roller Service Manual 47703722 - PDF DOWNLOAD

DV213 Tier 3 Vibratory Roller

SERVICE MANUAL

Printed in U.S.A. © 2015 CNH Industrial America LLC. All Rights Reserved.

Case is a trademark registered in the United States and many other countries, owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates.

Part number 47703722 2nd edition English September 2015 Replaces part number 84287246A

SERVICE MANUAL DV213

47703722 09/09/2015 EN

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

Engine....................................................................................... 10 [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2

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

Hydraulic systems....................................................................... 35 [35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.353] Hydraulic travel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.995] Compaction/vibration hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.500] Radiator cleaning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 [35.304] Combination pump units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5

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

Steering..................................................................................... 41 [41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1 [41.206] Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 [41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3

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

Cab climate control ..................................................................... 50 [50.100] Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1

47703722 09/09/2015

Electrical systems ....................................................................... 55 [55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.019] Hydrostatic drive control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 [55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system. . . . . . . . . . . . . . . . . 55.8 [55.518] Wiper and washer system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9 [55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10

Platform, cab, bodywork, and decals ............................................. 90 [90.120] Mechanically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 [90.105] Machine shields and guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2

47703722 09/09/2015

47703722 09/09/2015

INTRODUCTION

47703722 09/09/2015

1

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 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Hydraulic contamination – Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

47703722 09/09/2015

2

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.

47703722 09/09/2015

3

INTRODUCTION

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.

47703722 09/09/2015

4

INTRODUCTION

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.

47703722 09/09/2015

5

INTRODUCTION

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

47703722 09/09/2015

6

3

INTRODUCTION

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.

47703722 09/09/2015

7

INTRODUCTION

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.

47703722 09/09/2015

8

INTRODUCTION

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.

47703722 09/09/2015

9

6

INTRODUCTION

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

47703722 09/09/2015

10

INTRODUCTION

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

47703722 09/09/2015

11

INTRODUCTION

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

47703722 09/09/2015

12

INTRODUCTION

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.

47703722 09/09/2015

13

INTRODUCTION

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.

47703722 09/09/2015

14

INTRODUCTION

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)

47703722 09/09/2015

15

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

47703722 09/09/2015

16

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)

47703722 09/09/2015

17

INTRODUCTION

Special tools Group Drum

No. 1 2 3 4 5 6 7

8

Steering joint Hydraulic cylinder Radiator

9 10 11 12

Name - Use Handling sling Stop Handling clamp Lifting lug for handling Lifting hooks Adapter Tube Ø 129.0 mm (5.1 in) / Ø 105.0 mm (4.1 in) - L 120.0 mm (4.7 in) Tube Ø 139.0 mm (5.5 in) / Ø 115.0 mm (4.5 in) - L 140.0 mm (5.5 in) Ring Split ring Ø 70.0 mm (2.8 in) Split ring Ø 110.0 mm (4.3 in) Handling sling

Application Install/remove aux. transmission Lock drum position Handle the drum Install/remove vibrator Install/remove damper plates with flange and bearing Install and remove bolt Install and remove flange

Install/remove bearing

Install/remove bearing Install hydraulic cylinder piston Install hydraulic cylinder piston Install/remove radiator

1. Handling sling

SS12N433

1

SS12N434

2

2. Stop

47703722 09/09/2015

18

INTRODUCTION

3. Handling clamp

SS12N435

3

SS12N436

4

SS12N437

5

SS12N438

6

4. Lifting lug

5. Lifting hooks

6. Adapter

47703722 09/09/2015

19

INTRODUCTION

7. Tube / 8. Tube

SS12N439

7

SS12N440

8

SS12N441

9

9. Ring

10.Split ring / 11. Split ring

12. Handling sling

SS12N442

47703722 09/09/2015

20

10

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.

47703722 09/09/2015

21

INTRODUCTION

Consumables CASE CONINTERNATIONAL STRUCRECOMMENDED FLUIDS Specifications TIONSpecifiAND APPLICATION cations ENGINE - OIL Recommended oil: All seasons: CASE AKCELA SAE 15W - 40 NO. 1™ ENGINE OIL SAE SAE 10W - 30 15W-40 SAE 5W30 MAT 3507 Winter: CASE AKCELA API CF-4 NO. 1™ ENGINE OIL SAE API CI4 10W-30 API CJ-4 Extreme cold weather TUTELA AUTO SUPREME™ ENGINE OIL SAE 5W-30 COOLING SYSTEM CNH XHD HEAVY DUTY ASTM D6210 Type COOLANT / ANTI-FREEZE 1-FF antifreeze 50% water 50% HYDRAULIC SYSTEM API GL-4 CASE AKCELA HY-TRAN® MAT 3505 SAE 10W - ISO ULTRA™ HYDRAULIC VG-46 TRANSMISSION OIL FUEL TANK Ultra Low Sulfur Diesel (ULSD) SAE ASTM EN590 Decanted and filtered diesel ASTM D975 fuel (Sulfur not exceeding 15 mg/kg) DRUM BEARINGS, CALIPER BEARING, KING PINS, SUSPENSIONS, MAT 3550 NLGI 2 MACHINE ARTICULATION: TUTELA MULTI -PURPOSE EP GREASE 251H, GR-9 GLASS WASHER TANK SPRINKLING TANK

Water

–

VIBRATION DRUM CASE AKCELA NO. 1™ ENGINE OIL SAE 15W-40 PLANETARY FINAL DRIVE GEARBOX TUTELA HYPOIDE EP GEAR LUBE SAE 80W-90 TANDEM PUMP DRIVE GEARBOX TUTELA HYPOIDE EP GEAR LUBE SAE 80W-90

MAT 3507

QUANTITY

ALL

11.6 L (3.06 US gal)

ALL

21 L (5.55 US gal)

ALL

60 L (15.9 US gal)

ALL

210 L (55 US gal)

ALL

As required

ALL

2.75 L (0.73 US gal) 1000 L (264.17 US gal)

ALL

AIR-CONDITIONING COMPRESSOR CNH PAG OIL or PAG SP20 BRAKE SYSTEM CASE AKCELA DOT 4 FLUID

MODELS

ALL

Contact your dealer

SAE J1703 SAE J1704 ISO 4925 NHTSA 116-DOT 4

ALL

1.75 L (0.46 US gal)

SAE 15W - 40

ALL

2x 19 L (5.02 US gal)

2x 2.5 L (0.66 US gal) MAT 3511

API GL-5 SAE 80W - 90

ALL 1.8 L (0.48 US gal)

47703722 09/09/2015

22

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.

47703722 09/09/2015

23

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

47703722 09/09/2015

24

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!

47703722 09/09/2015

25

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.

47703722 09/09/2015

26

INTRODUCTION

Product identification Pos. Designation 1 Production label 2 Machine’s production number 3 Roll Over Protective Structure (ROPS) cab label

SS12C051

1

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

RAIL14COM0348BA

Engine serial number can be found in the location identified in the illustration.

SS12C591

47703722 09/09/2015

27

3

2

INTRODUCTION

Product identification

SS12C592

Pos. 1 2 3 4 5 6 7 8 9

Designation

1

Pos. 10 11 12 13

Front frame Rear frame Front drum Rear drum Engine Hydrogenerator for travel (roll) and vibration of front runner Hydrogenerator for travel (roll) and vibration of rear runner Travel hydraulic motor Vibration hydraulic motor

14 15

Designation Steering joint Hydraulic tank Batteries Cab with integrated Roll Over Protective Structure (ROPS) Fuel tank Sprinkling tank

16

Sprinkling jets

17 18

Scrapers Air filter

47703722 09/09/2015

28

SERVICE MANUAL Machine completion and equipment DV213

47703722 09/09/2015

05

Contents Machine completion and equipment - 05

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

47703722 09/09/2015

05

Machine completion and equipment - 05 Machine completion - 102

DV213

47703722 09/09/2015

05.1 [05.102] / 1

Contents Machine completion and equipment - 05 Machine completion - 102

TECHNICAL DATA Machine completion General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

47703722 09/09/2015

05.1 [05.102] / 2

Machine completion and equipment - Machine completion

Machine completion - General specification Weight Operating weight of CECE with cab, ROPS Operating weight of CECE with platform, rail Operating weight of CECE with platform, 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 (ISO 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 ROPS Weight of sheet roof on ROPS Weight of canopy Weight of canopy posts (version without ROPS) Weight of Edge cutter Weight of diagonal cutter

13080 kg (28836 lb) 12650 kg (27888 lb) 12960 kg (28572 lb) 6610 kg (14573 lb) 6470 kg (14264 lb) 590 kg (1301 lb) 13670 kg (30137 lb) 13870 kg (30578 lb) 14500 kg (31967 lb) 31.5 kg per centimeter ( 176.4 lb per inch) 30.8 kg per centimeter ( 172.5 lb per inch) 700 kg (1543 lb) 700 kg (1543 lb) 70 kg (154 lb) 40 kg (88 lb) 100 kg (220 lb) 100 kg (220 lb) 200 kg (440 lb)

Driving characteristics Maximum transport speed Climbing ability without vibration Climbing ability with vibration Lateral static stability Lateral stability during driving without vibration Lateral stability during driving with vibration Turning radius inner (edge) Turning radius outer (contour) Type of drive Number of driving axles Oscillation angle Angle of steering

11.4 km/h (7.1 mph) 4% 30% 65 25% 15% 4670 mm (183.9 in) 6880 mm (271 in) Hydrostatic 2 ± 6° ± 34°

Steering Type of steering Steering control Linear hydraulic motors

Joint Hydraulic 2+1 (Crab)

47703722 09/09/2015

05.1 [05.102] / 3

Machine completion and equipment - Machine completion

Engine Manufacturer Type Power according to DIN 6271 Power according to ISO 3046/1 Number of cylinders Cylinder capacity Nominal speed Maximum torque Routine operation fuel consumption Engines complies with emission regulations Cooling system of engine

Cummins QSB4.5-C130 97 kW (130 Hp) 97 kW (130 Hp) 4 4500 cm³ (275 in³) 2300 RPM 512 N·m (378 lb ft) at 1600 RPM 11.6 L/hour (3.1 US gal/hour) EU Stage IIIA, U.S. EPA Tier 3 Liquid

Brakes Hydrostatic Mechanical multiple-disc Mechanical multiple-disc

Operating Parking Emergency

Vibration 0.4 mm (0.016 in) 0.8 mm (0.031 in) 42 Hz (2520 vibrations per minute) 55 Hz (3300 vibrations per minute) 96 kN 135 kN 50 Hz (3000 vibrations per minute) 116 kN Hydrostatic

Small amplitude Large amplitude Low frequency High frequency Low centrifugal force High centrifugal force High frequency CE Centrifugal force CE Type of drive

Watering Type of watering Number of pumps Number of filtrations

Pressure 2 3

Wiring Voltage Battery capacity

12 V 135 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) Level of sound pressure affecting operator (platform)

47703722 09/09/2015

05.1 [05.102] / 4

82 dB 108 dB <0.5 m/s² (<1.6 ft/s²) 4.7 m/s² (15.4 ft/s²) 92 dB

Machine completion and equipment - Machine completion

Machine completion - Dimension

SS13F341

A 3525 mm (138.8 in)

D 1350 mm (53.1 in)

H1 3060 mm (120.5 in)

1

H4 335.0 mm (13.2 in)

47703722 09/09/2015

05.1 [05.102] / 5

L 4875 mm (191.9 in)

S 20 mm (0.8 in)

Machine completion and equipment - Machine completion

SS13G146

H2 2390 mm (94.1 in)

H3 770.0 mm (30.3 in)

O 61.0 mm (2.4 in)

2

W1 2100 mm (82.7 in)

47703722 09/09/2015

05.1 [05.102] / 6

W2 2222 mm (87.5 in)

W3 160 mm (6.3 in)

Index Machine completion and equipment - 05 Machine completion - 102 Machine completion - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Machine completion - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

47703722 09/09/2015

05.1 [05.102] / 7

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

PRINTED IN U.S.A. © 2015 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.

47703722 09/09/2015 EN

SERVICE MANUAL Engine DV213

47703722 09/09/2015

10

Contents Engine - 10

[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2

47703722 09/09/2015

10

Engine - 10 Engine and crankcase - 001

DV213

47703722 09/09/2015

10.1 [10.001] / 1

Contents Engine - 10 Engine and crankcase - 001

FUNCTIONAL DATA Engine Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Engine Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

47703722 09/09/2015

10.1 [10.001] / 2

Engine - Engine and crankcase

Engine - Component identification

SS12N328

1

47703722 09/09/2015

10.1 [10.001] / 3

Engine - Engine and crankcase

Pos. 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19 20 21 23 24 25 27 28 29 30 31 33 34 35 36

Designation Cover holder Holder Holder Filter holder Cover Holder Bracket Bracket Ring Cummins engine Transmission Coupling Pump Rubber mounting Contactor Connecting pipe Connecting pipe Connecting pipe Hose Hose Hose Hose Clip Elbow Ring Sleeve Clip Cover Bolt Bolt Bolt Bolt

Pos. 37 38 39 40 41 42 43 44 45 46 47 48 49 50 52 53 54 55 56 57 58 59 64 65 66 67 68 72 73 74 75

Designation Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Nut Nut Washer Bolt Spring washer Washer Washer Washer Ground strap Washer Washer Bolt Hose Fuel filter Gear pump Nut Bolt Washer Spring washer Connecting pipe Terminal Terminal Protective cover

47703722 09/09/2015

10.1 [10.001] / 4

Engine - Engine and crankcase

SS12N329

2

47703722 09/09/2015

10.1 [10.001] / 5

Engine - Engine and crankcase

Pos. 1 2 3 4 5 6 7 8 9 10 11 12

Designation Elbow Exhaust pipe Filter holder Terminal Reducing piece Yoke Yoke Air cleaner Hose Intake cover Knee pipe Coupling

Pos. 13 14 15 16 17 18 19 20 21 22 23

Designation Clip Clip Clip Clip Bracket Exhaust muffler Nut Indicator Washer Washer Bolt

47703722 09/09/2015

10.1 [10.001] / 6

Engine - Engine and crankcase

Engine - Remove WARNING Unexpected machine movement!

Make sure that you secure the machine with wheel chocks before you perform this procedure.

Failure to comply could result in death or serious injury.

W1221A

WARNING Rotating parts!

Always shut the engine off and disconnect the battery master switch before opening the hood.

Failure to comply could result in death or serious injury.

W1072A

1. Remove the hood (refer to Engine hood - Remove (90.105)).

2. Remove the battery (Refer to Battery - Remove (55.302)).

3. Cut off the straps holding the hoses and wiring to gain access to the engine compartment.

SS12N633

1

SS12N642

2

4. Drain the coolant from the engine.

47703722 09/09/2015

10.1 [10.001] / 7

Engine - Engine and crankcase

5. Remove the intake duct from the radiator. Cover the hoses and ports with protective caps.

SS12N636

3

SS12N637

4

SS12N638

5

SS12N639

6

6. Remove the clamp which secures the duct on the turbocharger. Remove the duct and cover the hoses and ports with protective caps.

7. Disconnect the air filter sensor. Remove the air intake hose.

47703722 09/09/2015

10.1 [10.001] / 8

Engine - Engine and crankcase

8. Remove the air filter.

SS12N640

7

SS12N641

8

SS12N643

9

9. Remove the air filter bracket.

10. Disconnect the coolant hoses at the drain valve.

11. Remove the temperature sensor and coolant hose.

SS12N663

47703722 09/09/2015

10.1 [10.001] / 9

10

Engine - Engine and crankcase

12. Remove the coolant hose. Cover the hoses and ports with protective caps.

SS12N644

11

SS12N645

12

SS12N646

13

SS12N647

14

13. Remove the hose clamp and bracket.

14. Disconnect the connector. Remove the hose from the cooling hydraulic motor. Cover the hoses and ports with protective caps.

47703722 09/09/2015

10.1 [10.001] / 10

Engine - Engine and crankcase

15. Remove the bolts securing the cooling fan to the radiator.

SS12N648

15

SS12N649

16

SS12N650

17

SS12N651

18

16. Remove the cooling fan together with the cooling hydraulic motor.

17. Remove the air discharge hose from the turbocharger.

18. Remove the turbocharger guard.

47703722 09/09/2015

10.1 [10.001] / 11

Engine - Engine and crankcase

19. Remove the flange from the turbocharger.

SS12N652

19

SS12N685

20

SS12N686

21

SS12N687

22

20. Remove the exhaust duct from the turbocharger.

21. Remove the hose clamp.

47703722 09/09/2015

10.1 [10.001] / 12

Engine - Engine and crankcase

22. Remove the hoses from the pump. Cover the hoses and ports with protective caps.

SS12N688

23

SS12N689

24

SS12N690

25

SS12N691

26

23. Remove the hose from the top of the pump. Cover the hoses and ports with protective caps.

24. Move all hoses away from and secure them with cable ties.

47703722 09/09/2015

10.1 [10.001] / 13

Engine - Engine and crankcase

25. Remove the brake-off hose.

SS12N692

27

SS12N693

28

SS12N694

29

SS12N695

30

26. Remove the hoses from the steering block and auxiliary transmission brake-off.

27. Disconnect the quick coupling from the steering block.

28. Remove the steering block.

47703722 09/09/2015

10.1 [10.001] / 14

Engine - Engine and crankcase

29. Remove the hoses from the side of the second pump.

Cover the hoses and ports with protective caps.

SS12N696

31

SS12N698

32

SS12N613

33

SS12N699

34

30. Remove the hoses from the top of the second pump.

Cover the hoses and ports with protective caps.

31. Remove the hose from the bottom of the pumps.

Cover the hoses and ports with protective caps.

32. Mark and disconnect the connectors of the solenoids on the bottom of the pumps (vibrations - low and high amplitude and travel - forward and rearward).

47703722 09/09/2015

10.1 [10.001] / 15

Engine - Engine and crankcase

33. Mark and disconnect the connectors of the solenoids on the top of the pumps (vibrations - low and high amplitude and travel - forward and rearward).

SS12N700

35

SS12N702

36

SS12N703

37

SS12N704

38

34. Disconnect the fuse connector.

35. Disconnect the cables from the connector.

36. Disconnect the glow plug cables.

47703722 09/09/2015

10.1 [10.001] / 16

Engine - Engine and crankcase

37. Remove the master disconnect switch.

SS12N705

39

SS12N674

40

SS12N706

41

SS12N707

42

38. Disconnect the cables for the relays, starter motor and engine preheating.

39. Remove the fuel return line.

40. Cover the fuel line and secure it on the fuel tank.

47703722 09/09/2015

10.1 [10.001] / 17

Engine - Engine and crankcase

41. Close the valve. Detach the fuel suction hose.

SS12N708

43

SS12N709

44

SS12N710

45

SS12N711

46

42. Detach the thermo-controller hoses.

43. Remove the heating system hose.

44. Remove the oil dipstick.

47703722 09/09/2015

10.1 [10.001] / 18

Engine - Engine and crankcase

45. Remove the hoses and cables from the bracket.

SS12N712

47

SS12N713

48

SS12N675

49

SS12N653

50

46. Disconnect the alternator wiring.

47. Disconnect the engine ground connection.

48. Detach the coolant hose running from the engine to the radiator.

47703722 09/09/2015

10.1 [10.001] / 19

Engine - Engine and crankcase

49. Remove the hoses from the pump. Cover the hoses and ports with protective caps.

SS12N619

51

SS12N618

52

SS12N654

53

SS12N655

54

50. Remove the hose flanges from the pump. Cover the hoses and ports with protective caps.

51. Disconnect the connectors from the engine.

47703722 09/09/2015

10.1 [10.001] / 20

Engine - Engine and crankcase

52. Disconnect the fuel level sensor connector.

SS12N656

55

SS12N657

56

SS12N658

57

SS12N659

58

53. Remove the front engine mount.

54. Remove the rear engine mounts.

55. Lift the engine with a suitable lifting device of adequate capacity and place it on a pedestal with sufficient load capacity.

NOTICE: The lifting device should have a minimum lifting capacity of 700 kg (1543 lb).

47703722 09/09/2015

10.1 [10.001] / 21

Engine - Engine and crankcase

56. Remove the pumps from the engine. Lift the pumps with a lifting device of adequate capacity.

SS12M327

59

SS12M153

60

SS12N660

61

SS12N661

62

57. Remove the pump housing. Lift the pump housing with a lifting device of adequate capacity.

58. Remove the clutch hub.

47703722 09/09/2015

10.1 [10.001] / 22

Engine - Engine and crankcase

59. Remove the flange.

SS12N662

47703722 09/09/2015

10.1 [10.001] / 23

63

Engine - Engine and crankcase

Engine - Install WARNING Unexpected machine movement!

Make sure that you secure the machine with wheel chocks before you perform this procedure.

Failure to comply could result in death or serious injury.

W1221A

WARNING Rotating parts!

Always shut the engine off and disconnect the battery master switch before opening the hood.

Failure to comply could result in death or serious injury.

W1072A

WARNING Heavy objects!

Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders.

Failure to comply could result in death or serious injury.

W0398A

1. Apply LOCTITE® 262™ to the threads of the bolts and install flange. Torque the bolts to 49 N·m (36.14 lb ft).

2. Install the clutch hub.

(51.63 lb ft).

SS12N662

1

SS12N661

2

Torque the bolts to 70 N·m

47703722 09/09/2015

10.1 [10.001] / 24

Engine - Engine and crankcase

3. Lift the pump housing with a lifting device of adequate capacity and install on the engine.

SS12N660

3

SS12M153

4

SS12M327

5

SS12N659

6

4. Lift the pumps with a lifting device of adequate capacity and install on the pump housing.

5. Lift the engine with a suitable lifting device of adequate capacity and place it on its correct installation position.

NOTICE: The lifting device should have a minimum lifting capacity of 700 kg (1543 lb).

47703722 09/09/2015

10.1 [10.001] / 25

Engine - Engine and crankcase

6. Install the rear engine mounts.

SS12N658

7

SS12N657

8

SS12N656

9

7. Install the front engine mount.

8. Connect the fuel level sensor connector.

47703722 09/09/2015

10.1 [10.001] / 26

Engine - Engine and crankcase

9. Connect the engine connectors.

SS12N654

10

SS12N655

11

SS12N618

12

SS12N619

13

10. Remove the protective caps. Install the hose flanges on the pump.

11. Remove the protective caps. Install the hoses on the pump.

47703722 09/09/2015

10.1 [10.001] / 27

Engine - Engine and crankcase

12. Install the coolant hose between the engine and the radiator.

SS12N653

14

SS12N675

15

SS12N713

16

SS12N712

17

13. Connect the engine ground connection.

14. Connect the alternator wiring.

15. Secure the hoses and cables on the bracket with the hardware removed earlier.

47703722 09/09/2015

10.1 [10.001] / 28

Engine - Engine and crankcase

16. Install the oil dipstick.

SS12N711

18

SS12N710

19

SS12N709

20

SS12N708

21

17. Install the heating system hose.

18. Install the thermo-controller hoses.

19. Install the fuel suction hose on the valves.

47703722 09/09/2015

10.1 [10.001] / 29

Engine - Engine and crankcase

20. Remove the protective caps. Install the fuel return line.

SS12N706

22

SS12N674

23

SS12N705

24

SS12N704

25

21. Connect the cables for the relays, starter motor and engine preheating.

22. Install the master disconnect switch.

23. Connect the glow plug cables.

47703722 09/09/2015

10.1 [10.001] / 30

Engine - Engine and crankcase

24. Connect the cables from the connector shown.

SS12N703

26

SS12N702

27

SS12N700

28

SS12N699

29

25. Connect the fuse connector.

26. Connect the connectors of the solenoids on the top of the pumps.

NOTICE: Make sure that the connected to their correct solenoids (vibrations - low and high amplitude and travel forward and rearward). Use the identification marks made during disconnection.

27. Connect the connectors of the solenoids on the bottom of the pumps.

NOTICE: Make sure that the connected to their correct solenoids (vibrations - low and high amplitude and travel forward and rearward). Use the identification marks made during disconnection.

47703722 09/09/2015

10.1 [10.001] / 31

Engine - Engine and crankcase

28. Remove the protective caps. Install the hose on the bottom of the pumps.

SS12N613

30

SS12N698

31

SS12N696

32

29. Remove the protective caps. Install the hoses on the top of the second pump.

30. Remove the protective caps. Install the hoses on the side of the second pump.

47703722 09/09/2015

10.1 [10.001] / 32

Engine - Engine and crankcase

31. Install the steering block in its correct position and connect the quick coupling.

SS12N695

33

SS12N694

34

SS12N693

35

SS12N692

36

32. Install the hoses on the steering block and auxiliary transmission brake-off.

33. Install the brake-off hose.

47703722 09/09/2015

10.1 [10.001] / 33

Engine - Engine and crankcase

34. Remove the protective caps. Install the hose on the top of the pump.

SS12N690

37

SS12N689

38

SS12N688

39

SS12N687

40

35. Remove the protective caps. Install the hoses on the pump.

36. Secure the hoses with the hose clamp as shown.

47703722 09/09/2015

10.1 [10.001] / 34

Engine - Engine and crankcase

37. Install the exhaust duct on the turbocharger.

SS12N686

41

SS12N685

42

SS12N652

43

SS12N651

44

38. Install the flange on the turbocharger.

39. Install the turbocharger guard.

47703722 09/09/2015

10.1 [10.001] / 35

Engine - Engine and crankcase

40. Install the air discharge hose on the turbocharger.

SS12N650

45

SS12N649

46

SS12N648

47

SS12N647

48

41. Install the cooling fan on the radiator with the bolts removed earlier.

42. Remove the protective caps. Remove the hose from the cooling hydraulic motor.

43. Disconnect the connector.

47703722 09/09/2015

10.1 [10.001] / 36

Engine - Engine and crankcase

44. Secure the hoses with the hose clamp and bracket.

SS12N646

49

SS12N644

50

SS12N645

51

SS12N663

52

45. Remove the protective caps. Install the coolant hose.

46. Install the temperature sensor and coolant hose.

47703722 09/09/2015

10.1 [10.001] / 37

Engine - Engine and crankcase

47. Connect the coolant hoses.

SS12N643

53

SS12N641

54

SS12N640

55

SS12N639

56

48. Install the air filter bracket.

49. Install the air filter.

50. Connect the air filter sensor.

51. Install the air intake hose.

47703722 09/09/2015

10.1 [10.001] / 38

Engine - Engine and crankcase

52. Install the duct on the turbocharger with the clamps removed earlier.

SS12N638

57

SS12N636

58

SS12N637

59

SS12N633

60

53. Remove the protective caps. Install the intake duct on the radiator.

54. Secure the hoses and cables in their correct location with cable ties.

55. Install the hood (refer to Engine hood - Install (90.105)).

56. Install the battery (refer to Battery - Install (55.302)).

47703722 09/09/2015

10.1 [10.001] / 39

Engine - Engine and crankcase

57. Install the fuel suction hose on the valves.

SS12N708

58. Refill the machine with service fluids (engine oil, coolant, etc...).

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

60. Top up the service fluids as necessary.

47703722 09/09/2015

10.1 [10.001] / 40

61

Index Engine - 10 Engine and crankcase - 001 Engine - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Engine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

47703722 09/09/2015

10.1 [10.001] / 41

47703722 09/09/2015

10.1 [10.001] / 42

Engine - 10 Engine cooling system - 400

DV213

47703722 09/09/2015

10.2 [10.400] / 1

Contents Engine - 10 Engine cooling system - 400

FUNCTIONAL DATA Radiator Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Radiator Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

47703722 09/09/2015

10.2 [10.400] / 2

Engine - Engine cooling system

Radiator - Component identification

SS12N330

1

47703722 09/09/2015

10.2 [10.400] / 3

Engine - Engine cooling system

Pos. 1 2 3 4 5 6 7 8 9 10 11 13 14 15 16 17 19 20 21 22 23 24 25

Designation Collar Coupling Grille Mask Elbow Left-hand panel Holder Plug Knee pipe Knee pipe Insulation Elbow Elbow Elbow Cooler Cooling air fan Rubber mounting Hydromotor Sending unit Coupling Connecting pipe Gasket Hose

Pos. 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 45 46 48 49

Designation Hose Hose Hose Hose Hose clamp Clip Clip Clip Clip Bolt Bolt Bolt Bolt Bolt Nut Nut Washer Washer Washer Ring Spring washer Plug

47703722 09/09/2015

10.2 [10.400] / 4

Engine - Engine cooling system

Radiator - Remove WARNING Burn hazard!

Hot coolant can spray and scald if you remove the radiator or deaeration tank cap while the system is hot. To remove the cap: allow the system to cool, turn the cap to the first notch, and wait for all pressure to release. Remove the cap only after all pressure has released.

Failure to comply could result in death or serious injury.

W0367A

WARNING Heavy objects!

Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders.

Failure to comply could result in death or serious injury.

W0398A

NOTE: For more details refer to Radiator - Component identification (10.400).

NOTICE: Position a drain collector pan under the radiator.

1. Remove the hood (refer to Engine hood - Remove (90.105).

2. Drain the coolant from the engine.

SS12N642

47703722 09/09/2015

10.2 [10.400] / 5

1

Engine - Engine cooling system

3. Remove the intake duct from the radiator. Cover the hoses and ports with protective caps.

SS12N636

2

SS12N637

3

SS12N638

4

SS12N639

5

4. Remove the clamp which secures the duct on the turbocharger. Remove the duct and cover the hoses and ports with protective caps.

5. Disconnect the air filter sensor connector. Remove the air intake hose.

47703722 09/09/2015

10.2 [10.400] / 6

Engine - Engine cooling system

6. Remove the air filter.

SS12N640

6

SS12N641

7

SS12N644

8

SS12N645

9

7. Remove the air filter bracket.

8. Detach the coolant hose. Cover the hoses and ports with protective caps.

47703722 09/09/2015

10.2 [10.400] / 7

Engine - Engine cooling system

9. Remove the temperature sensor and coolant hose.

SS12N663

10

SS12N647

11

SS12N648

12

SS12N649

13

10. Disconnect the connector. Remove the hose from the cooling hydraulic motor. Cover the hoses and ports with protective caps.

11. Remove the bolts which secures the cooling fan on the radiator.

12. Remove the cooling fan together with the cooling hydraulic motor.

47703722 09/09/2015

10.2 [10.400] / 8

Engine - Engine cooling system

13. Remove the air discharge hose from the turbocharger.

SS12N664

14

SS12N665

15

SS12N672

16

SS12N653

17

14. Remove the hydraulic-oil and coolant hoses.

15. Remove the drain hose.

16. Remove the coolant hose between the engine and radiator.

47703722 09/09/2015

10.2 [10.400] / 9

Engine - Engine cooling system

17. Remove the hydraulic-oil hose from the thermo-controller.

SS12N666

18

SS12N131

19

SS12N667

20

SS12M268

21

18. Remove the grille.

19. Remove the center rubber mountings on both sides.

20. Secure the radiator with the lifting lugs (10) (refer to Special tools ()) and lifting device of adequate capacity.

47703722 09/09/2015

10.2 [10.400] / 10

Engine - Engine cooling system

21. Remove the nuts and radiator mounts.

SS12N668

22

SS12N130

23

SS12N129

24

22. Lift the radiator and remove from the machine.

47703722 09/09/2015

10.2 [10.400] / 11

Engine - Engine cooling system

Radiator - Install WARNING Burn hazard!

Hot coolant can spray and scald if you remove the radiator or deaeration tank cap while the system is hot. To remove the cap: allow the system to cool, turn the cap to the first notch, and wait for all pressure to release. Remove the cap only after all pressure has released.

Failure to comply could result in death or serious injury.

W0367A

WARNING Heavy objects!

Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders.

Failure to comply could result in death or serious injury.

W0398A

1. Lift the radiator with the lifting lugs (10) (refer to Special tools ()) and lifting device of adequate capacity. Position in the engine compartment in its correct installation position.

SS12N130

1

SS12M268

2

SS12N668

3

2. Install the radiator mounts and nuts.

47703722 09/09/2015

10.2 [10.400] / 12

Engine - Engine cooling system

3. Install the grille.

SS12N131

4

SS12N666

5

SS12N653

6

SS12N672

7

4. Install the hydraulic-oil hose on the thermo-controller.

5. Install the coolant hose between the engine and radiator.

6. Remove the drain hose.

47703722 09/09/2015

10.2 [10.400] / 13

Engine - Engine cooling system

7. Install the hydraulic-oil and coolant hoses.

SS12N665

8

SS12N664

9

8. Install the air discharge hose on the turbocharger.

9. Install the cooling fan on the radiator with the bolts removed earlier.

47703722 09/09/2015

10.2 [10.400] / 14

SS12N649

10

SS12N648

11

Engine - Engine cooling system

10. Remove the protective caps. Install the hose on the cooling hydraulic motor.

11. Connect the connector.

SS12N647

12

SS12N663

13

SS12N645

14

SS12N644

15

12. Install the temperature sensor and coolant hose.

13. Remove the protective caps. Install the coolant hose.

47703722 09/09/2015

10.2 [10.400] / 15

Engine - Engine cooling system

14. Install the air filter bracket.

SS12N641

16

SS12N640

17

SS12N639

18

SS12N638

19

15. Install the air filter.

16. Connect the air filter sensor connector.

17. Install the air intake hose.

18. Remove the protective caps. Install the duct on the turbocharger with the clamps removed earlier.

47703722 09/09/2015

10.2 [10.400] / 16

Engine - Engine cooling system

19. Remove the protective caps. Install the intake duct on the radiator.

20. Refill the engine coolant.

21. Install the hood (Refer to Engine hood - Install (90.105) 22. Start the engine and check for serviceability and leaks.

23. Top up the coolant if necessary.

47703722 09/09/2015

10.2 [10.400] / 17

SS12N637

20

SS12N636

21

Index Engine - 10 Engine cooling system - 400 Radiator - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Radiator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Radiator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

47703722 09/09/2015

10.2 [10.400] / 18

47703722 09/09/2015

10.2 [10.400] / 19

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

PRINTED IN U.S.A. © 2015 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.

47703722 09/09/2015 EN

SERVICE MANUAL Hydrostatic drive DV213

47703722 09/09/2015

29

Contents Hydrostatic drive - 29

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

47703722 09/09/2015

29

Hydrostatic drive - 29 Pump and motor components - 218

DV213

47703722 09/09/2015

29.1 [29.218] / 1

Contents Hydrostatic drive - 29 Pump and motor components - 218

FUNCTIONAL DATA Pump and motor components Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Pump Measure relief pressures of front drum drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Measure relief pressures of rear drum drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Adjust vibration frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

47703722 09/09/2015

29.1 [29.218] / 2

Hydrostatic drive - Pump and motor components

Pump and motor components - Component identification

SS12N328

1

47703722 09/09/2015

29.1 [29.218] / 3

Hydrostatic drive - Pump and motor components

Pos. 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19 20 21 23 24 25 27 28 29 30 31 33 34 35 36

Designation Cover holder Holder Holder Filter holder Cover Holder Bracket Bracket Ring Cummins engine Transmission Coupling Pump Rubber mounting Contactor Connecting pipe Connecting pipe Connecting pipe Hose Hose Hose Hose Clip Elbow Ring Sleeve Clip Cover Bolt Bolt Bolt Bolt

Pos. 37 38 39 40 41 42 43 44 45 46 47 48 49 50 52 53 54 55 56 57 58 59 64 65 66 67 68 72 73 74 75

Designation Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Nut Nut Washer Bolt Spring washer Washer Washer Washer Ground strap Washer Washer Bolt Hose Fuel filter Gear pump Nut Bolt Washer Spring washer Connecting pipe Terminal Terminal Protective cover

47703722 09/09/2015

29.1 [29.218] / 4

Hydrostatic drive - Pump and motor components

SS12N332

2

47703722 09/09/2015

29.1 [29.218] / 5

Hydrostatic drive - Pump and motor components

Pos. 1 2 5 6 9 10 13 17 21 22 23 26 27 31 32 36 37 38 40 41 42 44 45 46 48 49 52 54 57 60 61 62

Designation Cube Holder Connection Orifice plate Steel plate Clamp Pipe Steering block Quick coupling Quick coupling Quick coupling Cover Cover Measuring connector Quick coupling Connecting pipe Connecting pipe Connecting pipe Connecting pipe Connecting pipe Connecting pipe Connecting pipe Connecting pipe Connecting pipe Connecting pipe Connecting pipe Connecting pipe Connecting pipe Bolt Hose Hose Hose

Pos. 63 64 65 67 68 72 73 74 76 79 80 83 84 87 89 90 92 93 95 97 100 101 102 103 104 107 110 111 112 113 117

Designation Hose Hose Hose Hose Hose Coupling Elbow Coupling Coupling T coupling T coupling T coupling T coupling Clip Cup nut Cup nut Sealing ring Sealing ring Ring Ring Bolt Bolt Bolt Bolt Bolt Nut Spring washer Washer Spring washer Washer Link tape

47703722 09/09/2015

29.1 [29.218] / 6

Hydrostatic drive - Pump and motor components

SS12N335

3

47703722 09/09/2015

29.1 [29.218] / 7

Hydrostatic drive - Pump and motor components

Pos. 1 2 5 9 10 11 14 18 19 20 23

Designation Clip Clip Hydromotor Connecting pipe Connecting pipe Connecting pipe Coupling Hose Hose Hose Hose

Pos. 24 25 26 30 31 32 35 36 39 40

Designation Hose Hose Hose Yoke O-ring Bolt Bolt Spring washer Link tape Link tape

47703722 09/09/2015

29.1 [29.218] / 8

Hydrostatic drive - Pump and motor components

SS12N334

4

47703722 09/09/2015

29.1 [29.218] / 9

Hydrostatic drive - Pump and motor components

Pos. 1 2 6 9 10 11 14 15 16 17 21

Designation Clip Clip Hydromotor Hose Hose Hose Hose Hose Hose Hose Connecting pipe

Pos. 22 24 27 31 32 33 36 37 38 41

Designation Connecting pipe Connecting pipe Coupling Yoke O-ring Bolt Bolt Nut Spring washer Link tape

47703722 09/09/2015

29.1 [29.218] / 10

Hydrostatic drive - Pump and motor components

Pump - Measure relief pressures of front drum drive Rearward drive - pump top: (5075 psi)

Forward drive - pump bottom: (5075 psi)

35 MPa - 350 bar

SS12M049

1

SS12M051

2

SS12M052

3

SS12M053

4

35 MPa - 350 bar

Low amplitude - pump top: 30 MPa - 300 bar (4350 psi)

High amplitude - pump bottom: 30 MPa - 300 bar (4350 psi)

47703722 09/09/2015

29.1 [29.218] / 11

Hydrostatic drive - Pump and motor components

Additional pressure - pump top: 20 MPa - 200 bar (2900 psi) NOTE: Following replacement or repair of the pump you must adjust the parameters of travel control unit and also adjust vibration frequency. Contact your nearest dealer to adjust travel control unit parameters! To adjust the vibration parameters , refer to Pump - Adjust vibration frequency (29.218).

SS12M050

47703722 09/09/2015

29.1 [29.218] / 12

5

Hydrostatic drive - Pump and motor components

Pump - Measure relief pressures of rear drum drive Forward drive – pump top: 35 MPa - 350 bar (5075 psi)

SS12M042

1

SS12M043

2

SS12M044

3

SS12M048

4

Rearward drive – pump bottom: 35 MPa - 350 bar (5075 psi)

High amplitude – pump top: (4350 psi)

30 MPa - 300 bar

Low amplitude – pump bottom: 30 MPa - 300 bar (4350 psi) NOTE: Following replacement or repair of the pump you must adjust the parameters of travel control unit and also adjust vibration frequency. Contact your nearest dealer to adjust travel control unit parameters! To adjust the vibration parameters , refer to Pump - Adjust vibration frequency (29.218).

47703722 09/09/2015

29.1 [29.218] / 13

Hydrostatic drive - Pump and motor components

Pump - Adjust vibration frequency WARNING Avoid injury!

Always turn OFF the engine before adjusting the vibration frequency.

Failure to comply could result in death or serious injury.

W1122A

To adjust vibration, first check and, if necessary, adjust the engine’s max RPM. 1. Check frequency values with the roller at standstill, and placed on an engine bench, or on tires laid down or on soft ground at max engine speed (adjusted to 2290 RPM).

2. Position the measuring instrument probe onto the drum jacket.

3. Switch ON vibration only on the drum being measured.

NOTICE: The max. total time of vibrator run with no drum turning over (bearing lubrication) is two minutes!

SS12M040

1

SS12M041

2

SS12M036

3

NOTE: Alternatively, you can position the measuring instrument probe on the damper plate. When measuring this way, you may read (pick up) vibrator frequency during machine drive.

4. Use Allen screws ( (1), low amplitude) and ( (2), high amplitude) to adjust the frequency after having slackened the lock nut (counter-nut) of the vibration pump ( (6), for front drum), ( (7), for rear drum) with the engine turned off.

5. Slacken (counter-clockwise turning) to increase the frequency and tighten (clockwise turning) to decrease the frequency.

6. Start the engine.

7. Check the set value again with the engine running.

47703722 09/09/2015

29.1 [29.218] / 14

Hydrostatic drive - Pump and motor components

Vibration frequency set values The roller is CE certified Amplitude Amplitude

low high

51.5 - 0.5 Hz 43.5 - 0.5 Hz

The roller has no CE value Amplitude Amplitude

low high

56.5 - 0.5 Hz 43.5 - 0.5 Hz

47703722 09/09/2015

29.1 [29.218] / 15

Index Hydrostatic drive - 29 Pump and motor components - 218 Pump - Adjust vibration frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Pump - Measure relief pressures of front drum drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Pump - Measure relief pressures of rear drum drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Pump and motor components - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

47703722 09/09/2015

29.1 [29.218] / 16

47703722 09/09/2015

29.1 [29.218] / 17

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

PRINTED IN U.S.A. © 2015 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.

47703722 09/09/2015 EN

SERVICE MANUAL Hydraulic systems DV213

47703722 09/09/2015

35

Contents Hydraulic systems - 35

[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.353] Hydraulic travel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.995] Compaction/vibration hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.500] Radiator cleaning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 [35.304] Combination pump units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5

47703722 09/09/2015

35

Hydraulic systems - 35 Hydraulic systems - 000

DV213

47703722 09/09/2015

35.1 [35.000] / 1

Contents Hydraulic systems - 35 Hydraulic systems - 000

FUNCTIONAL DATA Hydraulic systems Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

47703722 09/09/2015

35.1 [35.000] / 2

47703722 09/09/2015

35.1 [35.000] / 3

Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic schema Pos. 1 A B 2 3 4 5 C D 6 7 8 9 10 11 12 13 14 E F 15 16 17 18 19 20 21 22 23 24 25 26 27

Designation Combination pumps Front pump Rear Pump Steering and cooling pump Front travel hydrostatic motor Rear travel hydrostatic motor Vibration hydrostatic motors Front vibration hydrostatic motor Rear vibration hydrostatic motor Fan hydraulic motor Steering cylinder Crab cylinder Edge cutter cylinder (Optional) Lifting cylinder Steering valve Combined cooler Hydraulic reservoir Steering control unit (VX700) Crab control valve Edge cutter control valve (optional) Filter Thermoregulator Thermoregulator check valve Intake strainer Filler neck Safety block Hand pump Oil level sensor Temperature switch 97.0 - 103.0 °C (206.6 - 217.4 °F) Temperature switch 79.0 - 85.0 °C (174.2 - 185.0 °F) / 71.0 - 77.0 °C (159.8 - 170.6 °F) Oil level indicator Ball valve Measuring quick coupler

47703722 09/09/2015

35.1 [35.000] / 4

Hydraulic systems - Hydraulic systems

RAIL14COM0391JA

1

47703722 09/09/2015

35.1 [35.000] / 5

Hydraulic systems - Hydraulic systems

47703722 09/09/2015

35.1 [35.000] / 6

Index Hydraulic systems - 35 Hydraulic systems - 000 Hydraulic systems - Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

47703722 09/09/2015

35.1 [35.000] / 7

47703722 09/09/2015

35.1 [35.000] / 8

Hydraulic systems - 35 Hydraulic travel system - 353

DV213

47703722 09/09/2015

35.2 [35.353] / 1

Contents Hydraulic systems - 35 Hydraulic travel system - 353

SERVICE Travel motor Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Travel reduction gear Compaction front drum bearings and carriers - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

47703722 09/09/2015

35.2 [35.353] / 2

Hydraulic systems - Hydraulic travel system

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

1. Place an oil drain collector under the travel hydrostatic motor. Drain the reducer oil.

SS12N122

1

SS12K562

2

SS12K563

3

SS12K564

4

2. Disconnect the RPM sensor connector.

3. Remove the hoses and cover the hoses and ports.

4. Remove the hydrostatic motor.

47703722 09/09/2015

35.2 [35.353] / 3

Hydraulic systems - Hydraulic travel system

5. Check the O-ring and replace if necessary.

SS12K565

47703722 09/09/2015

35.2 [35.353] / 4

5

Hydraulic systems - Hydraulic travel system

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

1. Install the O-ring on the hydrostatic motor.

SS12K565

1

SS12K564

2

SS12K563

3

2. Install the hydrostatic motor with the bolts removed earlier. Torque the bolts to 200 N·m (147.5 lb ft).

3. Install the hoses on the hydrostatic motor.

47703722 09/09/2015

35.2 [35.353] / 5

Hydraulic systems - Hydraulic travel system

4. Connect the RPM sensor connector.

5. Fill the oil in the reduction motor.

SS12K562

47703722 09/09/2015

35.2 [35.353] / 6

4

Hydraulic systems - Hydraulic travel system

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

1. Remove the travel hydrostatic motor (Refer to Travel motor - Remove (35.353)).

2. Lift the machine just enough to relieve the weight on the drums. Make sure that the drums are in contact with the ground.

SS12N114

1

SS12N113

2

SS12N112

3

3. Remove the oil filler plug.

4. Secure the right-hand side bracket on a lifting device of adequate capacity.

5. Remove the bolts which attaches the right-hand side bracket on the cross-member.

6. Remove the bolts which attaches the right-hand side bracket on the frame.

47703722 09/09/2015

35.2 [35.353] / 7

Hydraulic systems - Hydraulic travel system

7. Remove the bolts attaching the bracket to the travel motor.

SS12N111

4

SS12N110

5

SS12N109

6

SS12N108

7

8. Remove the right-hand side bracket.

9. Install the toll (1) (Refer to Special tools ()) on the reduction gear.

10. Secure the tool (1) with a lifting device of adequate capacity.

11. To facilitate the installation in the correct location, mark the position of the carrier on the drum.

47703722 09/09/2015

35.2 [35.353] / 8

Hydraulic systems - Hydraulic travel system

12. Remove the bolts (15). Remove the carrier.

SS12N107

8

SS12N106

9

13. Remove the bolts which attach the reduction gear (23) on the carrier.

14. Remove the reduction gear.

47703722 09/09/2015

35.2 [35.353] / 9

Hydraulic systems - Hydraulic travel system

Travel reduction gear - Install 1. Install the reduction gear (23) on the carrier with the bolts removed earlier. Torque the bolts to 200 N·m (147.51 lb ft).

SS12N106

1

SS12N109

2

SS12N108

3

SS12N107

4

2. Install the tool (1) (refer to Special tools ()) on the carrier.

3. Lift the carrier with a lifting device of adequate capacity and place it on the drum.

NOTICE: Make sure that the carrier is placed in its correct location on the drum. Use identification marks made during removal procedure.

4. Install the carrier (15) with the bolts removed earlier.

Torque the bolts to 83 N·m (61.22 lb ft).

47703722 09/09/2015

35.2 [35.353] / 10

Hydraulic systems - Hydraulic travel system

5. Lift the right-hand side bracket with a lifting device of adequate capacity and place it in its correct installation position.

SS12N110

5

SS12N111

6

SS12N112

7

SS12N113

8

6. Install the bracket on the reduction gear with the bolts removed earlier. Torque the bolts to 390 N·m (287.65 lb ft).

7. Install the right-hand side bracket on the frame and the cross-member with the bolts removed earlier. Torque the bolts to 675 N·m (497.85 lb ft) 8. Install the right-hand side bracket on the cross-member with the bolts removed earlier. Torque the bolts to 390 N·m (287.65 lb ft)

9. Install the oil filler plug.

47703722 09/09/2015

35.2 [35.353] / 11

Hydraulic systems - Hydraulic travel system

10. Lift the machine and remove the supports.

SS12N114

47703722 09/09/2015

35.2 [35.353] / 12

9

Index Hydraulic systems - 35 Hydraulic travel system - 353 Compaction front drum bearings and carriers - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Travel motor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Travel motor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Travel reduction gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

47703722 09/09/2015

35.2 [35.353] / 13

47703722 09/09/2015

35.2 [35.353] / 14

Hydraulic systems - 35 Compaction/vibration hydraulic system - 995

DV213

47703722 09/09/2015

35.3 [35.995] / 1

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

SERVICE Compaction/vibration motor Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

47703722 09/09/2015

35.3 [35.995] / 2

Hydraulic systems - Compaction/vibration hydraulic system

Compaction/vibration motor - Remove NOTICE: The below procedure shows the removal of the front drum vibrations motor (located on the left-hand side of the drum). The procedure is the same to remove the rear drum vibrations motor (located on the right-hand side of the drum).

1. Place an oil drain collector under the vibration hydrostatic motor.

SS12K554

1

SS12N126

2

SS12N123

3

2. Remove the hoses and cover the hoses and ports.

3. Remove the hydrostatic motor from the drum flange.

47703722 09/09/2015

35.3 [35.995] / 3

Hydraulic systems - Compaction/vibration hydraulic system

4. Remove the clutch cover from the clutch (20B).

SS13J023

4

SS13J024

5

SS13J025

6

SS12K560

7

5. Check the O-ring (59) and replace if necessary.

6. Remove the clutch (20B).

7. Remove the lock ring.

NOTE: The lock ring is part of the clutch. Install the clutch (20B) to the new vibration hydrostatic motor.

47703722 09/09/2015

35.3 [35.995] / 4

Hydraulic systems - Compaction/vibration hydraulic system

Compaction/vibration motor - Install NOTICE: The below procedure shows the installation of the front drum vibrations motor (located on the left-hand side of the drum). The procedure is the same to install the rear drum vibrations motor (located on the right-hand side of the drum).

1. Install the lock ring on the clutch.

SS12K560

1

SS13J025

2

SS12N669

3

2. Install the clutch (20B) on the hydrostatic motor. Do not tighten the bolts now.

3. Refer to the illustration in Compaction front drum Component identification (44.160) and position the hydrostatic motor on the flange (11), until the shaft stops at the bearing (7) 4. Measure the distance (X) between the cover face and the hub (A) of the clutch (20).

5. Adjust the position of the clutch hub (20B) so as to maintain the dimension (Z) within 3.7 - 4.3 mm (0.146 - 0.169 in).

47703722 09/09/2015

35.3 [35.995] / 5

Hydraulic systems - Compaction/vibration hydraulic system

6. Once the clutch hub (20B) is properly adjusted, torque the nuts to 35 N·m (25.8 lb ft).

SS13J025

4

SS13J024

5

SS13J023

6

SS12N123

7

7. Install the O-ring (59).

8. Install the clutch cover on the clutch (20B).

9. Apply LOCTITE® 577™ to the bolt threads and install the hydrostatic motor on the drum flange. Torque the bolts to 83 N·m (61.22 lb ft).

47703722 09/09/2015

35.3 [35.995] / 6

Hydraulic systems - Compaction/vibration hydraulic system

10. Install the hoses on the hydrostatic motor.

SS12N126

47703722 09/09/2015

35.3 [35.995] / 7

8

Index Hydraulic systems - 35 Compaction/vibration hydraulic system - 995 Compaction/vibration motor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Compaction/vibration motor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

47703722 09/09/2015

35.3 [35.995] / 8

Hydraulic systems - 35 Radiator cleaning system - 500

DV213

47703722 09/09/2015

35.4 [35.500] / 1

Contents Hydraulic systems - 35 Radiator cleaning system - 500

FUNCTIONAL DATA Blower hydraulic motor Motor - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Blower hydraulic motor Pump and motor components - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

47703722 09/09/2015

35.4 [35.500] / 2

Hydraulic systems - Radiator cleaning system

Motor - Component identification

SS12N333

1

47703722 09/09/2015

35.4 [35.500] / 3

Hydraulic systems - Radiator cleaning system

Pos. 1 2 4 7 11 12 13 14 17

Designation Switch Flange Flange Coupling Connecting Connecting Connecting Connecting Coupling

pipe pipe pipe pipe

Pos. 18 22 27 31 33 35 36 38 40

47703722 09/09/2015

35.4 [35.500] / 4

Designation Coupling T coupling Hose Hose Hose Hose Hose Hose Sealing ring

Hydraulic systems - Radiator cleaning system

Pump and motor components - Remove 1. Disconnect the connector.

SS12N624

1

SS12N625

2

SS12N626

3

SS12N671

4

2. Remove the supply and speed control hoses.

3. Remove the bolts which secure the fan on the radiator.

4. Remove the fan and hydraulic motor assembly

5. Remove the shaft nut and pull down the fan from hydraulic motor shaft.

47703722 09/09/2015

35.4 [35.500] / 5

Hydraulic systems - Radiator cleaning system

Blower hydraulic motor - Install 1. Install the fan on the hydraulic motor shaft with the shaft hut.

SS12N671

1

SS12N626

2

SS12N625

3

SS12N624

4

2. Install the fan on the radiator with the bolts removed earlier.

3. Install the supply and speed control hoses.

4. Connect the connector.

5. Check for any leaks.

47703722 09/09/2015

35.4 [35.500] / 6

Hydraulic systems - Radiator cleaning system

6. Start the engine and check for serviceability.

7. Top up the hydraulic oil if necessary.

47703722 09/09/2015

35.4 [35.500] / 7

Index Hydraulic systems - 35 Radiator cleaning system - 500 Blower hydraulic motor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Motor - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Pump and motor components - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

47703722 09/09/2015

35.4 [35.500] / 8

Hydraulic systems - 35 Combination pump units - 304

DV213

47703722 09/09/2015

35.5 [35.304] / 1

Contents Hydraulic systems - 35 Combination pump units - 304

SERVICE Combination pump units Pump and motor components - Remove the tandem pumps for vibration and travel . . . . . . . . . . . . . . . . . 3 Install the tandem pumps for vibration and travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

47703722 09/09/2015

35.5 [35.304] / 2

Hydraulic systems - Combination pump units

Pump and motor components - Remove the tandem pumps for vibration and travel DANGER Heavy objects!

Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders.

Failure to comply will result in death or serious injury.

D0076A

WARNING Unexpected machine movement!

Make sure that you secure the machine with wheel chocks before you perform this procedure.

Failure to comply could result in death or serious injury.

W1221A

WARNING Rotating parts!

Always shut the engine off and disconnect the battery master switch before opening the hood.

Failure to comply could result in death or serious injury.

W1072A

Place a oil collector pan under the pumps. Cover pump hoses and ports with protective plugs once removed.

SS12M103

1

NOTICE: Pump (6) can be removed directly from the machine. To remove the pump (7), pump (6) must be removed.

Removal of the pump (6) 1. Cut the cable ties which secures the hoses and wiring harnesses. Remove the steps.

SS12N611

47703722 09/09/2015

35.5 [35.304] / 3

2

Hydraulic systems - Combination pump units

2. Mark and disconnect the connectors from the solenoid valves (low/high amplitude vibrations and forward reverse travel) on the bottom of the pump (6).

SS12N612

3

SS12N613

4

SS12N614

5

SS12N134

6

3. Remove the hoses from the bottom of the pump (6).

4. Remove the hoses from the top of the pump (6).

5. Move the hoses from the work area.

47703722 09/09/2015

35.5 [35.304] / 4

Hydraulic systems - Combination pump units

6. Support the pump (6) with a lifting device of adequate capacity.

SS12N615

7

SS12M151

8

SS12N128

9

7. Remove the pump flange.

8. Carefully remove the pump (6) from the drive housing and out of the frame.

9. Lower the pump under the frame.

SS12M152

Removal of the pump (7) 1. Refer to the above steps and remove the pump (6).

47703722 09/09/2015

35.5 [35.304] / 5

10

Hydraulic systems - Combination pump units

2. Remove the brake-off hose.

SS12N692

11

SS12N693

12

SS12N694

13

SS12N133

14

3. Remove the steering block and brake-off hoses.

4. Disconnect the quick coupling from the steering block.

5. Remove the steering block and filter from the rear frame.

47703722 09/09/2015

35.5 [35.304] / 6

Hydraulic systems - Combination pump units

6. Remove the hoses from the pump (7). Cover the hoses and ports with protective caps.

SS12N696

15

SS12N700

16

SS12N615

17

SS12M151

18

7. Mark and disconnect the connectors from the solenoid valves (low/high amplitude vibrations and forward reverse travel) on the bottom of the pump (7).

8. Support the pump (7) with a lifting device of adequate capacity.

9. Remove the pump flange.

47703722 09/09/2015

35.5 [35.304] / 7

Hydraulic systems - Combination pump units

10. Carefully remove the pump (7) from the drive housing and out of the frame.

SS12N128

19

SS12M152

20

11. Lower the pump under the frame.

47703722 09/09/2015

35.5 [35.304] / 8

Hydraulic systems - Combination pump units

Combination pump units - Install the tandem pumps for vibration and travel DANGER Heavy objects!

Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders.

Failure to comply will result in death or serious injury.

D0076A

WARNING Unexpected machine movement!

Make sure that you secure the machine with wheel chocks before you perform this procedure.

Failure to comply could result in death or serious injury.

W1221A

WARNING Rotating parts!

Always shut the engine off and disconnect the battery master switch before opening the hood.

Failure to comply could result in death or serious injury.

W1072A

Installation of the pump (7) 1. Check the O-ring and replace if necessary.

SS12N132

1

SS12K620

2

2. Carefully lift the pump (7) and place it in its correct position in the drive housing.

47703722 09/09/2015

35.5 [35.304] / 9

Hydraulic systems - Combination pump units

3. Install the pump flange.

SS12M151

3

SS12N700

4

SS12N696

5

SS12N133

6

4. Connect the following connectors to the solenoid valves on the bottom of the pump (7).

A. Low amplitude - Vibrations solenoid B. High amplitude - Vibrations solenoid C. Forward - Travel solenoid D. Reverse - Travel solenoid NOTICE: Make sure the connectors are connected to their correct position. Use the identification marks made during the removal.

5. Remove the protective caps. Install the hoses on the pump (7).

6. Install the steering block and filter on the rear frame.

47703722 09/09/2015

35.5 [35.304] / 10

Hydraulic systems - Combination pump units

7. Connect the quick coupling on the steering block.

SS12N694

7

SS12N693

8

SS12N692

9

8. Install the steering block and brake-off hoses.

9. Install the brake-off hose.

10. Refer to the below steps and install the pump (6).

Installation of the pump (6) 1. Check the O-ring and replace if necessary.

SS12N132

47703722 09/09/2015

35.5 [35.304] / 11

10

Hydraulic systems - Combination pump units

2. Carefully lift the pump (6) and place it in its correct position in the drive housing.

SS12K620

11

SS12M151

12

SS12N614

13

SS12N613

14

3. Install the pump flange.

4. Install the hoses on the top of the pump (6).

5. Install the hoses on the bottom of the pump (6).

47703722 09/09/2015

35.5 [35.304] / 12

Hydraulic systems - Combination pump units

6. Connect the following connectors to the solenoid valves on the bottom of the pump (6).

A. Low amplitude - Vibrations solenoid B. High amplitude - Vibrations solenoid C. Forward - Travel solenoid D. Reverse - Travel solenoid NOTICE: Make sure the connectors are connected to their correct position. Use the identification marks made during the removal.

SS12N612

15

SS12N611

16

7. Install the steps.

8. Secure the hoses and wiring harnesses with cable ties.

9. Check for any leaks.

10. Start the engine and check for serviceability.

11. Top up the hydraulic fluid if necessary.

47703722 09/09/2015

35.5 [35.304] / 13

Index Hydraulic systems - 35 Combination pump units - 304 Combination pump units - Install the tandem pumps for vibration and travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Pump and motor components - Remove the tandem pumps for vibration and travel . . . . . . . . . . . . . . . . . . . . . . . . . 3

47703722 09/09/2015

35.5 [35.304] / 14

47703722 09/09/2015

35.5 [35.304] / 15

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

PRINTED IN U.S.A. © 2015 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.

47703722 09/09/2015 EN

SERVICE MANUAL Frames and ballasting DV213

47703722 09/09/2015

39

Contents Frames and ballasting - 39

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

47703722 09/09/2015

39

Frames and ballasting - 39 Vibratory roller - 500

DV213

47703722 09/09/2015

39.1 [39.500] / 1

Contents Frames and ballasting - 39 Vibratory roller - 500

SERVICE Damping system - vibration isolators Compaction front drum bearings and carriers - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

47703722 09/09/2015

39.1 [39.500] / 2

Frames and ballasting - Vibratory roller

Compaction front drum bearings and carriers - Replace NOTE: For more details refer to Compaction front drum - Component identification (44.160).

NOTICE: The procedure below is to replace the front drum vibration dampers. The procedure is identical for the rear drum.

Removal Vibration motor side 1. Lift the frame slightly to relieve the load on the vibration isolators.

SS12K601

1

SS12N608

2

SS12N609

3

2. Remove the bolts which attaches the vibration isolators (62) on the damper plate (3).

3. Remove the bolts which attaches the vibration isolators (62) on the bracket (8).

47703722 09/09/2015

39.1 [39.500] / 3

Frames and ballasting - Vibratory roller

4. Remove the vibration isolators.

SS12N610

4

SS12K606

5

SS12K607

6

SS12K608

7

Travel motor side 1. Lift the frame slightly to relieve the load on the vibration isolators.

2. Remove the bolts which attach the vibration isolators.

3. Make clearance between the drum and the carrier and remove the vibration isolators.

47703722 09/09/2015

39.1 [39.500] / 4

Frames and ballasting - Vibratory roller

Installation Vibration motor side 1. Position the vibration isolators in its correct position.

SS12N610

8

SS12N609

9

2. Install the vibration isolators (62) on the bracket (8) with the bolts removed earlier. Torque the bolts to 83 N·m (61.22 lb ft).

3. Install the vibration isolators (62) on the damper plate (3) with the bolts removed earlier. Torque the bolts to 83 N·m (61.22 lb ft).

SS12N608

47703722 09/09/2015

39.1 [39.500] / 5

10

Frames and ballasting - Vibratory roller

Travel motor side 1. Make clearance between the drum and the carrier and position the vibration isolators in its correct position.

SS12K608

11

SS12K607

12

2. Install the vibration isolators on the carrier with bolts removed earlier. Torque the bolts to 83 N·m (61.22 lb ft).

47703722 09/09/2015

39.1 [39.500] / 6

Index Frames and ballasting - 39 Vibratory roller - 500 Compaction front drum bearings and carriers - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

47703722 09/09/2015

39.1 [39.500] / 7

47703722 09/09/2015

39.1 [39.500] / 8

Frames and ballasting - 39 Frame - 100

DV213

47703722 09/09/2015

39.2 [39.100] / 1

Contents Frames and ballasting - 39 Frame - 100

FUNCTIONAL DATA Articulation frame pivot Tie rods - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Articulation frame pivot Tie rods - Remove the articulation joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install the articulation joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Disassemble the articulation joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Assemble the articulation joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Remove the articulation slew bearing (rotator bearing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Install the articulation slew bearing (rotator bearing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

47703722 09/09/2015

39.2 [39.100] / 2

Frames and ballasting - Frame

Tie rods - Component identification

SS12K410

1

47703722 09/09/2015

39.2 [39.100] / 3

Frames and ballasting - Frame

Pos. 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16 18 19

Designation Slew Safety pin Joint arm Cover Cover Pin Ring Pin Shim Ring Ring Ring Pin Packing piece Steel plate Bolt Bolt

Pos. 20 21 22 23 24 25 26 27 28 30 31 32 33 34 38 39

47703722 09/09/2015

39.2 [39.100] / 4

Designation Bolt Bolt Bolt Washer Spring washer Spring washer Washer Washer Cap Hydraulic cylinder Bearing Bearing Nipple Nipple Dust bellows Bolt

Frames and ballasting - Frame

SS13G118

Pos. 1 2 4

Designation Slew Bracket Blade

2

Pos. 5 6

47703722 09/09/2015

39.2 [39.100] / 5

Designation Washer Screw

Frames and ballasting - Frame

Tie rods - Remove the articulation joint DANGER Heavy objects!

Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders.

Failure to comply will result in death or serious injury.

D0076A

1. Lift the frame and place suitable supports under the rear and front frame on both the sides.

SS12K609

1

SS12K610

2

SS12K611

3

2. Remove the bolts, spring washers and lock plates (10) which secures the steering cylinder head pins.

3. Drive out the pins and detach the steering cylinder heads from the articulation joint. Retain the rings for installation.

4. Remove the bolts, spring washers and lock plates (10) which secures the steering cylinder rod end pins.

5. Drive out the pins and detach the cylinder rod ends from the frame. Retain the rings for installation.

47703722 09/09/2015

39.2 [39.100] / 6

Frames and ballasting - Frame

6. Remove the hydraulic cylinders from the brackets and store it under the frame.

NOTICE: Do not detach the hydraulic hoses from the cylinders.

SS12K612

4

SS12K613

5

SS12K614

6

SS12K615

7

7. Remove the bolts, spring washers and lock plate (10) which secures the crab cylinder rod end pin.

8. Drive out the pin and detach the crab cylinder rod end from the articulation joint. Retain the rings for installation.

9. Disconnect the crab position sensor connector.

10. Remove the crab position sensor.

11. Detach the hoses from the bracket and remove the bracket on the articulation joint.

47703722 09/09/2015

39.2 [39.100] / 7

Frames and ballasting - Frame

12. Remove the bolts, washers , plates and upper and lower brackets and release the articulation joint from the slew bracket.

NOTICE: Mark the yokes to facilitate reinstallation.

SS12K616

8

SS12M084

9

13. Remove the hood (see Engine hood - Remove (90.105)).

14. Remove the bearing grease nipples. Route the rope under the joint bearing as shown.

15. Connect the rope to the lifting device with shortening chain.

16. Lift the rear frame with a lifting device of adequate capacity.

NOTICE: Make sure that the lifting device is capable of lifting loads in excess of 6000 kg (13228 lb) and equipped with a hook and chain with an adjustable strands so that the length of individual strands can be adjusted..

17. Adjust chain length to balance the suspended rear frame. Swing the frame rearward by 8 - 10 cm (3 4 in) to enable steering ring removal.

SS12M085

10

SS12M075

11

18. Support the frame with suitable stands.

47703722 09/09/2015

39.2 [39.100] / 8

Frames and ballasting - Frame

19. Position a suitable lifting device under the articulation joint and support the articulation joint properly.

SS12M076

12

SS12M086

13

SS12K520

14

20. Remove the upper and lower brackets and release the articulation joint.

21. Remove the articulation joint.

47703722 09/09/2015

39.2 [39.100] / 9

Frames and ballasting - Frame

Articulation frame pivot - Install the articulation joint DANGER Heavy objects!

Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders.

Failure to comply will result in death or serious injury.

D0076A

1. Place the articulation joint on a suitable lifting device and place it under the front frame.

SS12K520

1

SS12M076

2

SS12M086

3

2. Lift and align the articulation joint to its correct position.

3. Install the front pin of the articulation joint on the front frame with the upper and lower brackets. Torque the bolts to 390 N·m (287.6 lb ft).

47703722 09/09/2015

39.2 [39.100] / 10

Frames and ballasting - Frame

4. Lift the rear frame and position it in its correct position with a lifting device of adequate capacity.

NOTICE: Make sure that the lifting device is capable of lifting loads in excess of 6000 kg (13228 lb) and equipped with a hook and chain with an adjustable strands so that the length of individual strands can be adjusted..

SS12M085

4

SS12K616

5

SS12K615

6

SS12K614

7

5. Attach the articulation joint on the slew bracket with the upper and lower brackets, plates, washers and bolts.

NOTICE: Make sure that the upper and lower brackets are installed in their correct position.

6. Install the bracket in its correct position on the articulation joint.

7. Secure the hoses on the bracket with cable ties.

8. Install the crab position sensor.

9. Connect the crab position sensor connector.

47703722 09/09/2015

39.2 [39.100] / 11

Frames and ballasting - Frame

10. Install the crab cylinder rod ends on the frame with the pins and rings.

11. Secure the rod end pins with the lock plates (10), spring washers and the bolts.

SS12K613

8

SS12K611

9

12. Install the steering cylinder rod ends on the frame with the pins and rings.

13. Secure the rod end pins with the lock plates (10), spring washers and the bolts.

14. Secure the steering cylinder head on the articulation joint with the rings and the pins.

15. Secure the cylinder head pins with the lock plates (10), spring washers and the bolts.

SS12K610

10

SS12M084

11

16. Remove rope and reinstall the bearing grease nipples.

47703722 09/09/2015

39.2 [39.100] / 12

Frames and ballasting - Frame

Articulation frame pivot - Disassemble the articulation joint 1. Remove the covers on both sides.

SS12M087

1

SS12M088

2

SS12M089

3

SS12M324

4

2. Drive out the pin (7) from the articulation joint arm (3).

NOTE: The bearing might come out together with pin due to the close tolerances. If the bearing came out of the arm, continue to Step 3.

3. Lift the inner cover of the articulation joint arm (3) and tap the bearing (31) out of the arm's eye.

4. Install the tool (9) (see Special tools ()) on the outer ring of the bearing (31).

47703722 09/09/2015

39.2 [39.100] / 13

Frames and ballasting - Frame

5. Remove the bearing with a puller.

SS12M090

5

SS12M091

6

6. Remove the pin (7) from the arm.

7. Press out the bearing (31) from the other side of the articulation joint with a suitable press.

47703722 09/09/2015

39.2 [39.100] / 14

Frames and ballasting - Frame

Articulation frame pivot - Assemble the articulation joint 1. Remove any old sealant on the mating surface and clean the contact surfaces. If new bearings are to be used, remove any preservations on the bearings and lubricate the bearings with grease.

SS12M092

1

SS12M093

2

SS12M094

3

SS12M095

4

2. Replace the dust bellows (38) on the inner cover.

3. Install the inner covers on the pin. Install the pin on the articulation joint arms as shown. Lubricate the pin and the inner covers.

4. Install the bearing. Do not push the bearing to its final position now.

47703722 09/09/2015

39.2 [39.100] / 15

Frames and ballasting - Frame

5. Install the bearing on the other side.

SS12M096

5

SS12M098

6

SS12M097

7

SS12M098

8

6. Apply sealant (caulking compound) and install the cover with the bolts removed earlier.

7. Push the bearing to its final position.

8. Apply sealant (caulking compound) to the contact surfaces.

47703722 09/09/2015

39.2 [39.100] / 16

Frames and ballasting - Frame

9. 16. Install the cover with the bolts removed earlier.

SS12M099

47703722 09/09/2015

39.2 [39.100] / 17

9

Frames and ballasting - Frame

Articulation frame pivot - Remove the articulation slew bearing (rotator bearing) Use an appropriate hoist (platform truck) to support and then remove the rotator.

1. Remove the bolts (22) which attaches the outer race of the bearing to the rear frame.

NOTICE: Access the bolts (21) from the inside of the rear frame.

SS12M326

1

SS12M100

2

2. Remove the bolts which attaches the inner race of bearing to the slewing bracket.

3. Remove the bearing from the slewing bracket.

47703722 09/09/2015

39.2 [39.100] / 18

Frames and ballasting - Frame

Articulation frame pivot - Install the articulation slew bearing (rotator bearing) 1. Install the inner race of the bearing on the slewing bracket with the bolts removed earlier.

SS12M100

1

SS12M101

2

SS12M102

3

SS12M326

4

2. Align the slewing bracket and bearing assembly on the rear frame in such a way that the marked hole in the outer race of the bearing matches with the gap in the contact surface of the rear frame

3. Install the bearing with the bolts (22) from the inside of the rear frame.

47703722 09/09/2015

39.2 [39.100] / 19

Index Frames and ballasting - 39 Frame - 100 Articulation frame pivot - Assemble the articulation joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Articulation frame pivot - Disassemble the articulation joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Articulation frame pivot - Install the articulation joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Articulation frame pivot - Install the articulation slew bearing (rotator bearing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Articulation frame pivot - Remove the articulation slew bearing (rotator bearing) . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Tie rods - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Tie rods - Remove the articulation joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

47703722 09/09/2015

39.2 [39.100] / 20

47703722 09/09/2015

39.2 [39.100] / 21

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

PRINTED IN U.S.A. © 2015 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.

47703722 09/09/2015 EN

SERVICE MANUAL Steering DV213

47703722 09/09/2015

41

Contents Steering - 41

[41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1 [41.206] Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 [41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3

47703722 09/09/2015

41

Steering - 41 Steering control - 101

DV213

47703722 09/09/2015

41.1 [41.101] / 1

Contents Steering - 41 Steering control - 101

FUNCTIONAL DATA Steering column Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Steering column Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

47703722 09/09/2015

41.1 [41.101] / 2

Steering - Steering control

Steering column - Component identification

SS12K408

1

47703722 09/09/2015

41.1 [41.101] / 3

Steering - Steering control

Pos. 2 3 4 5 6 7 8 9 10 11 12 14

Designation Slew Steel plate Steering column Limiter Washer Seat Bolt Rest Rest Switch Case Steering wheel

Pos. 16 17 18 20 21 22 23 24 25 26 27 28

47703722 09/09/2015

41.1 [41.101] / 4

Designation Switch Power steering Nut Countersunk screw Bolt Bolt Bolt Washer Spring washer Spring washer Washer Hose

Steering - Steering control

Steering column - Remove 1. Remove the instrument panel.

SS12M067

1

SS12M068

2

SS12M069

3

SS12M070

4

2. Remove the steering wheel adjustment lever.

3. Pull the dust bellow from the steering column.

4. Disconnect connector X-20.

47703722 09/09/2015

41.1 [41.101] / 5

Steering - Steering control

5. Remove the power steering hoses.

SS12M071

5

SS12M072

6

6. Remove the bolts.

7. Remove the power-steering unit from the steering column.

47703722 09/09/2015

41.1 [41.101] / 6

Steering - Steering control

Steering column - Install 1. Apply LOCTITE® 262™ to the threads of the bolts.

2. Install the power steering unit on the steering column with the bolts. Torque the bolts to 30 N·m (22.1 lb ft).

SS12M072

1

SS12M071

2

RAIL14COM0387AA

3

SS12M070

4

3. Install the power steering hoses.

4. Torque the fittings as follows:.

1.

35 N·m (25.8 lb ft)

2.

70 N·m (51.6 lb ft)

3.

90 N·m (66.4 lb ft)

4.

100 N·m (73.8 lb ft)

5. Connect connector X-20.

47703722 09/09/2015

41.1 [41.101] / 7

Steering - Steering control

6. Install the dust bellow on the steering column.

SS12M069

5

SS12M068

6

SS12M067

7

7. Install the steering wheel adjustment lever.

8. Install the instrument panel.

47703722 09/09/2015

41.1 [41.101] / 8

Index Steering - 41 Steering control - 101 Steering column - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Steering column - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Steering column - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

47703722 09/09/2015

41.1 [41.101] / 9

47703722 09/09/2015

41.1 [41.101] / 10

Steering - 41 Pump - 206

DV213

47703722 09/09/2015

41.2 [41.206] / 1

Contents Steering - 41 Pump - 206

SERVICE Power steering pump Transmission and steering hydrostatic control - Remove (Gear pump for steering) . . . . . . . . . . . . . . . . . . 3 Install (Gear pump for steering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

47703722 09/09/2015

41.2 [41.206] / 2

Steering - Pump

Transmission and steering hydrostatic control - Remove (Gear pump for steering) NOTE: For more details refer to Engine - Component identification (10.001).

1. Cut off the cable ties.

SS12N616

1

SS12N617

2

SS12N619

3

2. Remove the hoses. Cover the hoses and ports with protective caps.

NOTE: Place a drain collector pan under the pump to collect and drained oil.

3. Remove the hoses from the pump.

47703722 09/09/2015

41.2 [41.206] / 3

Steering - Pump

4. Remove the hose flanges from the pump. Cover the hoses and ports with protective caps.

SS12N618

4

SS12N620

5

SS12N621

6

SS12N622

7

5. Remove the bolts which secures the pump on the engine.

6. Remove the pump.

7. Check the O-ring for condition and replace if necessary.

47703722 09/09/2015

41.2 [41.206] / 4

Steering - Pump

8. Check the seal ring on the engine and replace if necessary.

SS12N623

8

SS12N135

9

9. Check the O-ring on the flange and replace if necessary.

47703722 09/09/2015

41.2 [41.206] / 5

Steering - Pump

Power steering pump - Install (Gear pump for steering) 1. Install the O-ring on the pump.

SS12N622

1

SS12N623

2

SS12N621

3

SS12N620

4

2. Install the seal ring on the pump seat of the engine.

3. Place the pump on the engine in its correct installation position..

4. Install the pump on the engine with the bolts removed earlier.

47703722 09/09/2015

41.2 [41.206] / 6

Steering - Pump

5. Install the O-rings on the hose flanges.

SS12N135

5

SS12N618

6

SS12N619

7

SS12N617

8

6. Remove the protective caps. Install the hose flanges on the pump.

7. Install the hoses on the hose flanges.

8. Remove the protective caps. Install the hoses.

47703722 09/09/2015

41.2 [41.206] / 7

Steering - Pump

9. Secure the hoses with the cable ties.

SS12N616

47703722 09/09/2015

41.2 [41.206] / 8

9

Index Steering - 41 Pump - 206 Power steering pump - Install (Gear pump for steering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Transmission and steering hydrostatic control - Remove (Gear pump for steering) . . . . . . . . . . . . . . . . . . . . . . . . . . 3

47703722 09/09/2015

41.2 [41.206] / 9

47703722 09/09/2015

41.2 [41.206] / 10

Steering - 41 Cylinders - 216

DV213

47703722 09/09/2015

41.3 [41.216] / 1

Contents Steering - 41 Cylinders - 216

FUNCTIONAL DATA Cylinders Steering cylinder - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Cylinders Steering cylinder - Remove the steering and crab cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install the steering and crab cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

47703722 09/09/2015

41.3 [41.216] / 2

Steering - Cylinders

Steering cylinder - Component identification

SS12K410

1

47703722 09/09/2015

41.3 [41.216] / 3

Steering - Cylinders

Pos. 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16 18 19

Designation

Pos. 20 21 22 23 24 25 26 27 28 30 31 32 33 34 38 39

Slew Safety pin Joint arm Cover Cover Pin Ring Pin Shim Ring Ring Ring Pin Packing piece Steel plate Bolt Bolt

Designation Bolt Bolt Bolt Washer Spring washer Spring washer Washer Washer Cap Hydraulic cylinder Bearing Bearing Nipple Nipple Dust bellows Bolt

NOTICE: Order the relevant sealants for the hydraulic cylinder used from your manufacturer. Be sure to state your machine's serial number.

Pos. 1 2 3 4 5 6

Pos. 1 2 3 4 5

Designation T19 Sealing T20 Collar Oil control rig Guide band Ring Ring

SS12N445

2

SS12N446

3

Designation Hydraulic cylinder body Piston rod Piston Nut Cover

47703722 09/09/2015

41.3 [41.216] / 4

Steering - Cylinders

Steering cylinder - Remove the steering and crab cylinders NOTICE: The below procedures show the removal of the right-hand side steering cylinder. The procedure is the same to remove the right-hand side and left-hand side steering cylinders and the crab cylinder. Differences (if any) are identified.

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

1. Remove the bolts, spring washers and lock plate (10) which secure the cylinder head pin.

SS12K610

1

SS12K611

2

SS12K612

3

2. Drive out the pin and detach the cylinder head from the articulation joint. Retain the rings for installation.

NOTE: In case of the crab cylinder, the cylinder head is attached to the frame.

3. Remove the bolts, spring washers and lock plate (10) which secure the steering cylinder rod end pin.

4. Drive out the pin and detach the cylinder rod end from the frame. Retain the rings for installation.

NOTE: In case of the crab cylinder, the cylinder rod end is attached to the articulation joint.

5. Remove the cylinder from the bracket.

6. Remove the hoses from the cylinder.

47703722 09/09/2015

41.3 [41.216] / 5

Steering - Cylinders

Cylinders - Install the steering and crab cylinders NOTICE: The below procedures show the installation of the right-hand side steering cylinder. The procedure is the same to install the right-hand side and left-hand side steering cylinders and the crab cylinder. Differences (if any) are identified.

1. Install the hoses on the cylinder.

SS12K612

1

SS12K611

2

SS12K610

3

2. Install the cylinder rod end on the frame with the pins and rings.

NOTE: In case of the crab cylinder, Install the cylinder rod end on the articulation joint.

3. Secure the rod end pins with the lock plates (10), spring washers and the bolts.

4. Secure the steering cylinder head on the articulation joint with the rings and the pins.

NOTE: In case of the crab cylinder, install the cylinder head on the frame.

5. Secure the cylinder head pins with the lock plates (10), spring washers and the bolts.

47703722 09/09/2015

41.3 [41.216] / 6

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.

47703722 09/09/2015

41.3 [41.216] / 7

Steering - Cylinders

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.

47703722 09/09/2015

41.3 [41.216] / 8

5

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) (See Special tools ()) in the cylinder barrel.

4. Insert the piston into the cylinder barrel.

47703722 09/09/2015

41.3 [41.216] / 9

Steering - Cylinders

5. Remove the tool from the cylinder barrel.

SS12K547

5

SS12K548

6

SS12K549

7

6. Install the cylinder gland.

7. Lock the cylinder gland.

47703722 09/09/2015

41.3 [41.216] / 10

Index Steering - 41 Cylinders - 216 Cylinders - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Cylinders - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Cylinders - Install the steering and crab cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Steering cylinder - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Steering cylinder - Remove the steering and crab cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

47703722 09/09/2015

41.3 [41.216] / 11

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

PRINTED IN U.S.A. © 2015 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.

47703722 09/09/2015 EN

SERVICE MANUAL Wheels DV213

47703722 09/09/2015

44

Contents Wheels - 44

[44.160] Compaction drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1

47703722 09/09/2015

44

Wheels - 44 Compaction drums - 160

DV213

47703722 09/09/2015

44.1 [44.160] / 1

Contents Wheels - 44 Compaction drums - 160

FUNCTIONAL DATA Compaction drums Compaction front drum - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Compaction drums Compaction front drum - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Compaction front drum bearings and carriers - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

47703722 09/09/2015

44.1 [44.160] / 2

Wheels - Compaction drums

Compaction front drum - Component identification

SS12N327

1

47703722 09/09/2015

44.1 [44.160] / 3

Wheels - Compaction drums

Pos. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Designation Drum Right bracket Damper plate Crossmember Bearing cover Sheet Distributor Left bracket Flange Shaft Fixed eccentric Fixed eccentric Free eccentric Free eccentric Carrier Distributor Ring Hydromotor Coupling Spring Bearing Aux. transmission Bush Plug Bleeder valve Magnetic plug Sealing ring Oil seal Gasket Bearing Nut Washer Locking sheet

Pos. 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 68 70 75 78

47703722 09/09/2015

44.1 [44.160] / 4

Designation Spacer Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Plate Nut Washer Bolt Washer Spring washer Washer Washer Spring washer Spring Bolt Ring Ring Sealing ring Rubber mounting Bolt Washer Nut Bolt

Wheels - Compaction drums

Compaction front drum - Remove WARNING Avoid injury!

Secure and support the front frame and the rear frame with suitable lifting equipment.

Failure to comply could result in death or serious injury.

W1223A

NOTICE: Procedure to remove the front drum is provided below. The removal process is identical for front and the rear drums.

1. Lift the machine just enough to relieve the weight on the drums. Make sure that the drums are in contact with the ground.

2. Place suitable supports and remove the jacks.

SS12N114

1

SS12K570

2

SS12M325

3

3. Make alignment marks on the drum and the ground on both sides to facilitate reinstallation.

4. Secure the drum against motion with the tool (2) (Refer to Special tools ()).

5. Remove the vibration hydrostatic motor (Refer to Compaction/vibration motor - Remove (35.995)).

6. Remove the travel hydrostatic motor (Refer to Travel motor - Remove (35.353)).

7. Remove the auxiliary transmission; refer to Compaction front drum bearings and carriers - Remove (44.160)

47703722 09/09/2015

44.1 [44.160] / 5

Wheels - Compaction drums

8. Secure the hoses away from the work area to prevent any interference with the drum removal.

SS12N105

4

SS12N104

5

SS13A886

6

SS12N103

7

9. Remove the sprinkling hose and sprinklers.

10. Secure the cross member on a lifting device of adequate capacity.

NOTICE: It is not possible to disconnect the front lights connector now. Rear drum lights can be disconnected at this step.

47703722 09/09/2015

44.1 [44.160] / 6

Wheels - Compaction drums

NOTICE: For the front drum, the wiring connector can be disconnected only when the drum is removed.

SS12N099

8

SS12N102

9

11. Remove the bolts attaching the left-hand side and right-hand side brackets to the cross-member.

12. Secure the right-hand side bracket on a lifting device of adequate capacity.

13. Remove the bolts attaching the bracket on the frame.

SS12K580

10

SS12K581

11

14. Remove the bolts attaching the bracket to the travel motor.

47703722 09/09/2015

44.1 [44.160] / 7

Wheels - Compaction drums

15. Support the left-hand bracket on a lifting device of adequate capacity.

16. Remove the bolts attaching the bracket on the frame.

SS13A885

12

SS12N098

13

SS12K583

14

SS12K584

15

17. Remove the bolts for mounting the bracket to the front drum one by one and lay it aside.

18. Secure the vibration motor hoses.

19. Secure the travel motor hoses.

20. Roll the drum out from the frame.

47703722 09/09/2015

44.1 [44.160] / 8

Wheels - Compaction drums

Compaction drums - Install WARNING Avoid injury!

Secure and support the front frame and the rear frame with suitable lifting equipment.

Failure to comply could result in death or serious injury.

W1223A

NOTICE: Procedure to install the front drum is provided below. The installation process is identical for front and the rear drums.

1. Roll the drum to its correct position. Make sure that the alignment marks made on the drum and the ground align on both sides

SS12K570

1

SS12M325

2

SS12K567

3

2. Once the drum is placed in its correct position, secure the drum against movement with the tools (2) (See Special tools ()).

3. Install the right-hand side bracket on the frame with the bolts removed earlier. Torque the bolts to 675 N·m (497.85 lb ft)

47703722 09/09/2015

44.1 [44.160] / 9

Wheels - Compaction drums

4. Install the right-hand side bracket on the travel motor with the bolts removed earlier. Torque the bolts to 200 N·m (147.5 lb ft) 5. Install the travel reduction gear (Refer to Travel reduction gear - Install (35.353)).

6. Install the travel hydrostatic motor (Refer to Travel motor - Install (35.353)).

SS12K581

4

SS12K566

5

SS12K578

6

SS12N098

7

7. Install the hoses to the travel motor and the reduction gear brake release.

8. Connect the RPM sensor connector.

9. Install the left-hand side bracket with the bolts removed earlier. Torque the bolts as follows: A. Bolts attaching the bracket on the drum: 83 N·m (61.2 lb ft) B. Bolts attaching the bracket to the frame: 675 N·m (497.85 lb ft) 10. Install the vibrations hydrostatic motor (Refer to Compaction/vibration motor - Install (35.995)).

47703722 09/09/2015

44.1 [44.160] / 10

Wheels - Compaction drums

11. Connect the front headlight wiring.

SS12K574

8

SS12K575

9

12. Lift and position the cross-member between the righthand side and left-hand side brackets with a lifting device of adequate capacity.

13. Install the bolts attaching the right-hand side and lefthand side brackets on the cross-member. Torque the bolts to 390 N·m (287.65 lb ft).

SS12K576

47703722 09/09/2015

44.1 [44.160] / 11

10

Wheels - Compaction drums

14. Install the sprinkling hose and sprinklers.

SS12N104

11

SS13A886

12

SS12N114

13

15. Lift the machine and remove the supports and jacks.

16. Check the machine for any leaks and serviceability.

17. Refill/top-up the systems with fluids as necessary.

47703722 09/09/2015

44.1 [44.160] / 12

Wheels - Compaction drums

Compaction front drum bearings and carriers - Disassemble DANGER Crushing hazard!

Support designated component(s) with adequate lifting equipment.

Failure to comply will result in death or serious injury.

D0091A

NOTE: For more details refer to Compaction front drum - Component identification (44.160).

Travel drive side 1. Install the clamp (3) (See Special tools ()) with a loading capacity of 3000 kg (6614 lb).

SS12N097

1

SS12N096

2

SS12N095

3

2. Position the drum upright on the support blocks with the vibration motor side resting on the ground.

3. Mark the position of the flange (9) and plate (6) to facilitate reinstallation.

4. Remove the bolts (42) of the flange (9).

47703722 09/09/2015

44.1 [44.160] / 13

Wheels - Compaction drums

5. Remove the flange (9) with the lifting lugs and lifting device of adequate capacity.

SS12N094

4

SS12N092

5

SS12N091

6

SS12N090

7

6. Remove the bolts which attaches the plate (6).

7. Install extractor bolts and push off the cover evenly.

8. Remove the bolts which attaches the distributor (7) and press out the bearing (31).

47703722 09/09/2015

44.1 [44.160] / 14

Wheels - Compaction drums

Vibration drive side 1. Install the clamp (3) (See Special tools ()) with a loading capacity of 3000 kg (6614 lb).

SS12N089

8

SS12N088

9

2. Position the drum upright on the support blocks with the travel motor side resting on the ground.

3. Mark the position of the flange assembly on the drum.

Remove the bolts of the flange (9).

SS12N087

47703722 09/09/2015

44.1 [44.160] / 15

10

Wheels - Compaction drums

4. Secure the flange assembly with a suitable lifting equipment.

NOTE: You may use ropes, steel bars and a lifting device as shown in the images.

SS12N085

11

SS12N670

12

SS12N086

13

SS12N084

14

5. Remove the flange (9) with the bolts used to push the flange off the drum.

6. Lift the flange assembly and place it on the workbench.

47703722 09/09/2015

44.1 [44.160] / 16

Wheels - Compaction drums

7. Remove the bearing cover bolts (5).

SS12N083

15

SS12N082

16

SS12N337

17

SS12N338

18

8. Remove the extractor bolts.

9. Push off the bearing cover.

10. Secure the slewing assembly on a lifting device and remove the bearing cover.

47703722 09/09/2015

44.1 [44.160] / 17

Wheels - Compaction drums

11. Remove the bolts for the distributor (17) and press out the bearing (31).

SS12N339

19

SS12N340

20

SS12N341

21

SS12N342

22

12. Remove the locking ring (34).

13. Remove the nut (32) with the tool (4) (See Special tools ()).

14. Remove the bolts on the extraction holes.

47703722 09/09/2015

44.1 [44.160] / 18

Wheels - Compaction drums

15. Install M14 X 100 bolts on the extraction holes and push the bearing cover (5) off the damper plate (3).

SS12N343

23

SS12N344

24

SS12N345

25

SS12N346

26

16. Remove the bearing cover (5) with lifting device of adequate capacity.

47703722 09/09/2015

44.1 [44.160] / 19

Wheels - Compaction drums

17. Remove the oil seal (29) and gasket (30) from the bearing cover.

18. Remove the bearing.

SS12N347

27

SS12N348

28

SS12N349

29

SS12N603

30

Vibration shaft 19. Install the lifting lug (6) (refer to Special tools ()) on the shaft and lift the shaft assembly.

Left-hand side 1. Remove the clutch (20).

2. Remove the lock ring (70).

47703722 09/09/2015

44.1 [44.160] / 20

Wheels - Compaction drums

3. Remove the nut with the tool (4) (refer to Special tools ()).

SS12N604

31

SS12N605

32

SS12N606

33

SS12N607

34

4. Remove the washer (33), bearing (31) and spacer (35) with a puller.

NOTICE: Do not disassemble the eccentrics (11) from the shaft.

Right-hand side 1. Remove the lock ring (70).

2. Remove the nut with the tool (4) (refer to Special tools ()).

3. Remove the washer (33), bearing (31) and spacer (35) with a puller.

47703722 09/09/2015

44.1 [44.160] / 21

Wheels - Compaction drums

Compaction drums - Assemble Travel drive side 1. Install the clamp (3) (See Special tools ()) with a loading capacity of 3000 kg (6614 lb).

SS12N097

1

SS12N096

2

SS12N090

3

SS12N092

4

2. Position the drum upright on the support blocks with the vibration motor side resting on the ground.

3. Install the bearing (31) on the flange.

4. Install the distributor with the bolts removed earlier.

5. Install the cover plate (6) with the bolts removed earlier.

Torque the bolts to 132.0 N·m (97.4 lb ft).

NOTICE: Make sure that the identification marks made on the cover plate (6) and the flange (9) during the disassembly are aligning properly.

47703722 09/09/2015

44.1 [44.160] / 22

Wheels - Compaction drums

6. Apply LOCTITE® 577™ on the mating surfaces of the flange and the drum.

7. Lift the flange (9) with the lifting lugs and lifting device of adequate capacity and place it on its correct installation location.

SS12N094

5

SS12N095

6

SS12N607

7

SS12N606

8

8. Install the flange (9) on the drum with the bolts (42) removed earlier. Torque the bolts to 132.0 N·m (97.4 lb ft).

Vibration shaft Right-hand side 9. Install the washer (33), bearing (31) and spacer (35) on the shaft.

10. Install the nut with the tool (4) (refer to Special tools ()).

11. Install the lock ring (70).

47703722 09/09/2015

44.1 [44.160] / 23

Wheels - Compaction drums

Left-hand side 12. Install the washer (33), bearing (31) and spacer (35).

SS12N605

9

13. Install the nut with the tool (4) (refer to Special tools ()).

SS12N604

10

SS12N603

11

SS12N349

12

14. Install the lock ring (70).

15. Install the clutch (20). Torque to 35 N·m (25.8 lb ft).

47703722 09/09/2015

44.1 [44.160] / 24

Wheels - Compaction drums

16. Install the shaft in the drum with the lifting lug (6) (refer to Special tools ()) and a lifting device of adequate capacity.

SS12N348

13

SS12N089

14

SS12N088

15

SS12N347

16

Vibration drive side NOTICE: Apply caulking compound to all mating surfaces before assembly.

1. Install the clamp (3) (See Special tools ()) with a loading capacity of 3000 kg (6614 lb).

2. Position the drum upright on the support blocks with the travel motor side resting on the ground.

3. Install the bearing on the bearing cover with a press.

4. Install the oil seal (29) and gasket (30) on the bearing cover.

47703722 09/09/2015

44.1 [44.160] / 25

Wheels - Compaction drums

5. Install the bearing cover (5) on the damper plate (3) with a press.

SS12N346

17

SS12N345

18

SS12N342

19

SS12N341

20

6. Install the bolts removed earlier on the extraction holes.

7. Install the nut (32) with the tool (4) (See Special tools ()). Torque the nut to 70 - 80 N·m (52 - 59 lb ft)

47703722 09/09/2015

44.1 [44.160] / 26

Wheels - Compaction drums

8. Install the locking ring (34).

SS12N340

21

SS12N339

22

SS12N338

23

SS12N337

24

9. Install the bearing (31) with a press.

10. Install the distributor (17) with the bolts removed earlier.

11. Place the slewing assembly on the bearing cover with a lifting device of adequate capacity.

12. Install the bearing cover on the slewing assembly with the bolts removed earlier. Torque the bolts to 132.0 N·m (97.4 lb ft).

47703722 09/09/2015

44.1 [44.160] / 27

Wheels - Compaction drums

13. Install the bearing cover bolts (5).

SS12N083

25

SS12N085

26

SS12N670

27

SS12N087

28

14. Lift the flange assembly with a suitable lifting equipment and place it on its correct installation location.

Use the identification marks made during the disassembly.

NOTE: You may use ropes, steel bars and a lifting device as shown in the images.

15. Apply LOCTITE® 577™ to the mating surfaces.

16. Pull the vibration shaft with the lifting lug and a lifting device and make sure that there an axial play of 1 2 mm (0.039 - 0.079 in).

17. Install the flange assembly (9) on the drum with the bolts removed earlier. Torque the bolts to 132.0 N·m (97.4 lb ft).

47703722 09/09/2015

44.1 [44.160] / 28

Index Wheels - 44 Compaction drums - 160 Compaction drums - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Compaction drums - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Compaction front drum - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Compaction front drum - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Compaction front drum bearings and carriers - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

47703722 09/09/2015

44.1 [44.160] / 29

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

PRINTED IN U.S.A. © 2015 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.

47703722 09/09/2015 EN

SERVICE MANUAL Cab climate control DV213

47703722 09/09/2015

50

Contents Cab climate control - 50

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

47703722 09/09/2015

50

Cab climate control - 50 Heating - 100

DV213

47703722 09/09/2015

50.1 [50.100] / 1

Contents Cab climate control - 50 Heating - 100

FUNCTIONAL DATA Heating Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Cab heater Heating - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

47703722 09/09/2015

50.1 [50.100] / 2

Cab climate control - Heating

Heating - Component identification

SS12N336

1

47703722 09/09/2015

50.1 [50.100] / 3

Cab climate control - Heating

Pos. 1 2 3 4 5 6 7 8 9 10 11

Designation Cover Clamp Hose Strap Heater Water valve Pull rod Connecting pipe Sleeve Cover Protection cover

Pos. 13 14 15 16 17 18 19 20 21 22 23

47703722 09/09/2015

50.1 [50.100] / 4

Designation Link tape Clip Symbol Bolt Bolt Bolt Bolt Nut Washer for wood Spring washer Spring washer

Cab climate control - Heating

Heating - Remove 1. Drain approximately 6 L (1.59 US gal) of engine coolant.

SS12N058

1

SS12M155

2

SS12M156

3

SS12M157

4

2. Remove the hoses.

3. Remove the cab heater housing.

4. Remove the cab heater.

47703722 09/09/2015

50.1 [50.100] / 5

Cab climate control - Heating

5. Remove the hoses (A) and bolts (B) of the heater.

SS12M158

47703722 09/09/2015

50.1 [50.100] / 6

5

Cab climate control - Heating

Cab heater - Install 1. Install the hoses (A) and bolts (B) on the heater.

SS12M158

1

SS12M157

2

SS12M156

3

SS12M155

4

2. Install the cab heater with the bolts removed earlier.

3. Install the hoses.

4. Refill the engine cooling system.

47703722 09/09/2015

50.1 [50.100] / 7

Cab climate control - Heating

5. Start the engine and check for any leaks and serviceability.

6. Top up with coolant if necessary.

47703722 09/09/2015

50.1 [50.100] / 8

Index Cab climate control - 50 Heating - 100 Cab heater - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Heating - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Heating - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

47703722 09/09/2015

50.1 [50.100] / 9

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

PRINTED IN U.S.A. © 2015 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.

47703722 09/09/2015 EN

SERVICE MANUAL Electrical systems DV213

47703722 09/09/2015

55

Contents Electrical systems - 55

[55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.019] Hydrostatic drive control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 [55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system. . . . . . . . . . . . . . . . . . . 55.8 [55.518] Wiper and washer system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9 [55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10

47703722 09/09/2015

55

Electrical systems - 55 Electrical system - 000

DV213

47703722 09/09/2015

55.1 [55.000] / 1

Contents Electrical systems - 55 Electrical system - 000

FUNCTIONAL DATA Electrical system Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

47703722 09/09/2015

55.1 [55.000] / 2

Electrical systems - Electrical system

Electrical system - Component identification ID A1

ID M5

Description Left rear window wiper

ID S27

A2

Description Direction indicator flasher unit Left instrument cluster

M6

Right rear window wiper

S28

A3

Right instrument cluster

M7

Windshield washer

S29

A4

Travel electronics

M8

Rear window washer

S30

A5

Travel controller

A6

Timing relay

Q1

Battery master switch

S32

B1

Fuel level float

R1

S33

B2 B3 B5

Coolant level sensor Water tank pressure sensor Drum speed sensor

R2 R3–5 R6

Watering interval potentiometer Speed potentiometer Resistor Engine preheating

R8 R9 S1 S2

Engine speed control Resistor Ignition switch Combined switch

M9-11 Fans

C1 E1-2 E3-4 E5-6

Noise suppression filter Front side lights Tail lights Front headlights

E7-8

Tail headlights

S2.1

E9-10 Left direction indicators

S2.2

E11-12 Right direction indicators E13-14 Auxiliary front headlights (option) E15-16 Auxiliary tail headlights (option) E17 Hazard warning beacon (option) E18-19 Brake lights E20 Cab light

S2.3 S2.4 S2.5 S3

Switch for side lights and headlights High/low beam control switch Headlight flasher switch Loud horn button Direction indicator control switch Tail headlight switch

S31

Washers double button Fan control switch Air conditioner switch (option) S37 Engine idle speed switch S38 Engine diagnostics switch S39 Troubleshooting switch S43 Hydraulics temperature switch – fan switch S44 Air conditioner overpressure fuse (option) V1-14 Light-emitting diode (LED) S34 S35 S36

V13 X1

Transil Mounting socket

X2

Diagnostic socket

X3-4

G1 G2

Battery Alternator

S7 S8

H1 H2

Low beam indicator light High beam indicator light

S9 S12

H3

Loud horn

S13

Hazard warning light switch Front auxiliary light switch (option) Hazard warning beacon switch (option) Brake pressure switch Clogged hydraulic system filter switch Clogged air filter switch Hydraulic oil overheating switch CRAB mode switch

H4

Acoustic warning device

S14

Reversing horn switch

Y6

H5

Reversing horn (option)

S15

Neutral gear switch

Y7

F1-16 Fuses

S4 S5 S6

47703722 09/09/2015

55.1 [55.000] / 3

Description Vibration amplitude control switch Left (yellow) button on the left travel controller - CRAB to the left Right (yellow) button on the left travel controller - CRAB to the right Left (yellow) button on the right travel controller - CRAB to the left or cutter up Right (yellow) button on the right travel controller - CRAB to the right or cutter down Windshield wiper control switch Rear window wiper switch

Connection terminals

X5-62 Interface connector X63 Engine diagnostics X64-69 Connectors J1939 X70-75 Connectors Y1 Engine cooling fan valve Y3 Y4 Y5

Brake valve Valve - front runner forward drive Valve - front runner reverse drive Valve - rear runner forward drive Valve - rear runner reverse drive

Electrical systems - Electrical system

ID H6 H7 H8

K1

Description Stop engine indicator light (red) Engine malfunction indicator light (yellow) WTS (Wait To Start) indicator light (white) – engine preheating Contactor

K2-17, Auxiliary relay 20 K18 Preheating relay

ID S16

Description Emergency brake button

ID Y8

S18

Y9

S19

Constant speed or stalling switch Vibration automatics switch

Y10

S20

Smooth start and stop button

Y11

S21

Seat switch

Y12

Front drum vibration high amplitude valve Valve for CRAB to the left

S22

Vibration button (red) on the left travel controller Vibration button (red) on the right travel controller Watering button Watering pumps control switch Vibration control switch – front/both/rear

Y13

Valve for CRAB to the right

Y14

Pressure relief valve

Y15 Y16

Valve for cutter up (option) Valve for cutter down (option) Air conditioner compressor clutch (option)

M1

Engine starter

S23

M2 M3

Watering motor Watering motor

S24 S25

M4

Windshield wiper

S26

47703722 09/09/2015

55.1 [55.000] / 4

Y17

Description Rear drum vibration low amplitude valve Rear drum vibration high amplitude valve Front drum vibration low amplitude valve

Index Electrical systems - 55 Electrical system - 000 Electrical system - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

47703722 09/09/2015

55.1 [55.000] / 5

47703722 09/09/2015

55.1 [55.000] / 6

Electrical systems - 55 Harnesses and connectors - 100

DV213

47703722 09/09/2015

55.2 [55.100] / 1

Contents Electrical systems - 55 Harnesses and connectors - 100

FUNCTIONAL DATA Wiring harnesses Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Electrical schematic sheet 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Electrical schematic sheet 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Electrical schematic sheet 03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Fuse and relay box Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

47703722 09/09/2015

55.2 [55.100] / 2

Electrical systems - Harnesses and connectors

Wiring harnesses - Component localization

SS12N498

1

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

SS12N461

47703722 09/09/2015

55.2 [55.100] / 3

2

Electrical systems - Harnesses and connectors

View A

SS12N460

3

SS12N462

4

SS12N676

5

SS12N677

6

View B

View C

View D Z

1 - 2 mm

47703722 09/09/2015

55.2 [55.100] / 4

Electrical systems - Harnesses and connectors

47703722 09/09/2015

55.2 [55.100] / 5

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 01 For the description of Component IDs, refer to Electrical system - Component identification (55.000).

47703722 09/09/2015

55.2 [55.100] / 6

Electrical systems - Harnesses and connectors

RAIL14COM0394JA

1

47703722 09/09/2015

55.2 [55.100] / 7

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 02

Pin details

For the description of Component IDs, refer to Electrical system - Component identification (55.000).

A2 – Left instrument cluster 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Warning Fuel gauge Neutral Vibration Hydraulic oil overheating Hydraulic oil level Instrument illumination Engine stop Ground

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Warning Water tank level Watering Constant speed Warning lights Instrument illumination Engine stop Ground

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

-5 V Engine overload Constant speed Smooth start-stop Seat Front drum - travel forward Front drum - travel backward Reference signal Reference signal Vibration RS2323 Ground +5 V Ground Engine speed Drum speed Neutral Automatic vibration RS2323 TxD RS2323 RxD

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

Brake Seat Hydraulic lter Charging + Engine hours Air lter Direction lights Direction lights Supply +12V

A3 – Right instrument cluster 11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

Air-conditioning system Crab Smooth start-stop Glowing Engine overload Supply +12V

A4 – Travel control unit

47703722 09/09/2015

55.2 [55.100] / 8

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

Rear drum - travel forward Rear drum - travel backward Vibration Sprinkling +12V Ground Ground Speed Travel Sprinkling Smooth start-stop Brake +12V

Electrical systems - Harnesses and connectors

RAIL14COM0395JA

1

47703722 09/09/2015

55.2 [55.100] / 9

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 03

1 A

For the description of Component IDs, refer to Electrical system - Component identification (55.000).

B

Optional Radio If the edge cutter is installed to left-hand side of the roller change over the plug X27 to socket X28. The switches S28 and S29 on the left control lever are used to lifting cutter.

If the edge cutter is installed to right-hand side of the roller change over the plug X29 in socket X30. The switches S30 and S31 on the left control lever are used to lifting cutter.

47703722 09/09/2015

55.2 [55.100] / 10

Electrical systems - Harnesses and connectors

RAIL14COM0396JA

1

47703722 09/09/2015

55.2 [55.100] / 11

Electrical systems - Harnesses and connectors

47703722 09/09/2015

55.2 [55.100] / 12

Electrical systems - Harnesses and connectors

Fuse and relay box - Component localization From the left-hand side Description Front, tail headlights Ceiling lights, light switches (contour light, tail light, indicator light F3 15 (30) A Horn, hazard warning beacon, auxiliary lights, light socket F4 5A Clusters F5 10 A Travel electronics, reversing horn F6 15 A Sprinkling F7 7.5 A Vibration, CRAB (edge cutter) F8 1A Engine diagnostics F15 30 A Cab power supply Connector 21 For controlling and adjusting control unit parameters F1 F2

Rating 20 A 15 A

SS12N673

1

SS12N684

2

SS12N682

3

SS12N681

4

Fuses – behind the master switch door Rating F9 F10 F16

30 A 125 A

Description Radio (as per manufacturer) ECM power supply Preheating

Fuses – after the panel is lifted off

From the left-hand side F11

Rating 15 A

F12 F13 F14 F15

15 A 5A 10 A 30 A

Description Windshield wipers and windshield washer Cooling air fans Cooling air fan control Air conditioner Cab power supply

47703722 09/09/2015

55.2 [55.100] / 13

Index Electrical systems - 55 Harnesses and connectors - 100 Wiring harnesses - Electrical schematic sheet 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Wiring harnesses - Electrical schematic sheet 03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Fuse and relay box - Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Wiring harnesses - Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Wiring harnesses - Electrical schematic sheet 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

47703722 09/09/2015

55.2 [55.100] / 14

Electrical systems - 55 Engine starting system - 201

DV213

47703722 09/09/2015

55.3 [55.201] / 1

Contents Electrical systems - 55 Engine starting system - 201

FUNCTIONAL DATA Engine starter Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Engine starter Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

DIAGNOSTIC Engine starting system Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

47703722 09/09/2015

55.3 [55.201] / 2

Electrical systems - Engine starting system

Engine starter - Static description • Proper operation of the starter is based on appropriate and fully charged batteries.

• The starter is designed for short-term operation. Continuous starting must not last more than 5 s.

• Once the engine starts, stop the start attempt – risk of damage to starter motor pinion and starter bearing.

• Feed cables must have cable heads perfectly tightened and insulation not disrupted.

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

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

• Check that the flywheel ring gear and bevel pinion are not worn out. Lubricate with grease when inspecting.

• Operations during engine repair or once every two years: Remove the machine starter. Check the collector, brushes, brush springs, and switch contact surfaces.

Make sure that 3/4 of the brush surface will contact the collector and that brushes slide easily. Contact surfaces of switch contacts must not be burnt and must contact each other with their entire surface.

47703722 09/09/2015

55.3 [55.201] / 3

Electrical systems - Engine starting system

Engine starter - Check Check the idling - on the machine 1. Check the starter is in a position that the bevel pinion does not mesh with the gear ring even when extended.

2. When starter circuit is switched ON, the bevel pinion must protrude and spin.

NOTE: An unloaded starter may operate for max. 10 s. For a detailed description of the check procedure, see “Informative inspection of starter”. Values measured must comply with those in the table.

Finding starter faults: 1. Connect the 30 terminal of the starter to a fully charged battery; connect an ammeter with long measuring range to the circuit.

2. Do not start (supply current to the 50 terminal). The current value while idling must not exceed 120 A (peak at instantaneous deflection will not be taken into account). The starter must run quietly. The bevel pinion must protrude continuously and return to its home position. When the bevel pinion is protruded, it should not spin right on the face of the cap ring. Starter runout (when the sensor is disconnected from the power supply) may last 8 s only.

3. Check the pressure and condition of the brush springs.

Brushes must be seated on the collector with at least 2/3 of the surface and must be able to move inside the chambers. The armature must have visible axial clearance of max 1.3 mm (0.05 in).

4. When the bevel pinion is turned slightly in the direction of starter rotation, the overrunning clutch must slip lightly. If you have sufficient experience, the no-load check is sufficient for workshop evaluation.

5. However, we recommend testing on the engine bench.

47703722 09/09/2015

55.3 [55.201] / 4

Electrical systems - Engine starting system

SS12N458

1

47703722 09/09/2015

55.3 [55.201] / 5

Electrical systems - Engine starting system

Engine starting system - Troubleshooting Problem Possible Cause Broken wire to switch’s 30 terminal The starter motor does not rotate when switched ON Broken wire to switch’s 50 terminal Ignition key/switch failed Burnt contacts

Starter runs idle

Starter does not go OFF – remains in mesh.

Immediately disconnect battery (ground terminal)

Correction Repair the wire.

Repair the wire.

Replace the ignition key/switch.

Replace the contacts and/or the entire cover (always together with bridge contacts).

Replace the starter motor switch.

Broken winding for starter motor switch Switch is short-circuited (poor tension, gets Replace the starter motor switch. heated) Release, clean and apply oil.

Switch armature remains hanging Damaged protruding (disengaging) mech- Replace or repair. anism Bevel pinion jams on the shaft Repair (shaft alignment is sometimes necessary).

Ignition key/switch failed Replace ignition key/switch.

Caked starter switch contacts Seized bevel pinion on shaft

Replace the contacts (together with bridge contacts or whole switch).

• Replace the pinion bearing.

• Remove sharp edges on the shaft.

Starter does not bring pinion into mesh Pinion is milling the flywheel Starter can be heard to engage bevel pinion but does not turn the engine over

Starter motor does not work reliably (low power)

Broken protruding (disengaging) spring

• Clean (check untrue running of the shaft).

Repair damaged rim and/or replace (find the cause).

Replace the spring.

Damaged pinion gearing Discharged battery

Replace the pinion (find the cause).

Recharge the battery.

Damaged flywheel rim

Damaged overrunning clutch – it slips (bro- Replace the clutch. ken bush) Burnt starter switch contacts Replace the contacts.

Recharge the battery.

Insufficiently charged battery Dirty or loosened connections in feed ca- Clean and tighten properly. bles (contact resistances) Battery malfunctions (normally slow deteri- Repair the battery fault. oration of starting) Damaged starter brushes Replace brushes (normally necessary to repair collector)

47703722 09/09/2015

55.3 [55.201] / 6

Electrical systems - Engine starting system

Problem

Possible Cause Correction Dirty and burnt and/or unsoldered collector • Clean with gasoline or alcohol. (commutator) • Clean with gasoline or alcohol.

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

• Mill out the insulation.

• Polish the commutator.

Loud starter motor operation

• If required, solder again and/or replace the armature (anchor).

Broken and/or heated up carbon brush Replace the spring. springs Armature short circuit Replace the armature.

Part of exciting coils is disconnected (inter- Replace relevant pair of coils. rupted) Starter switch failed (contact resistance) Replace ignition key/switch.

Stator excitation winding disrupted on the Solder again at the pin (outlet) point. cable to the starter switch terminal Tighten the bolts.

Starter loosened within its flange

Armature loosened (seized in bearings) Mechanical defect (various) Broken cap (max noise) Starter heats excessively, Short circuit within excitation circuit low performance

47703722 09/09/2015

55.3 [55.201] / 7

Repair it.

Repair the defect Repair/replace the cap.

Eliminate short circuit and/or replace relevant pair of coils.

Index Electrical systems - 55 Engine starting system - 201 Engine starter - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine starter - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine starting system - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

47703722 09/09/2015

55.3 [55.201] / 8

Electrical systems - 55 Alternator - 301

DV213

47703722 09/09/2015

55.4 [55.301] / 1

Contents Electrical systems - 55 Alternator - 301

FUNCTIONAL DATA Alternator Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Alternator Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

DIAGNOSTIC Alternator Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

47703722 09/09/2015

55.4 [55.301] / 2

Electrical systems - Alternator

Alternator - Static description The alternator is used as an electric power supply.

Integrated in the alternator is a semiconductor voltage controller. It keeps output voltage within its certain range at variable rpm, variable load, and at variable ambient temperature.

Controlled voltage alters on B+ terminal.

Cooling is provided via own fan with the direction of rotation marked thereon.

The alternator must always operate with the accumulator battery connected - positive battery pole connected to B+ terminal. Never disconnect a battery during operation.

Avoid any short circuits within the alternator vicinity. Disconnect alternator cables from the mains when wiring is to be repaired or welding carried out. When starting via an auxiliary external power supply, never disconnect the power supply before the battery is connected. The alternator must never run idle, i.e. with the wire disconnected from B+ terminal and D+ terminal connected.

Immediately replace the recharging indicator light if defective. Alternator excitation will not be provided for if the charging indicator light is not working. Avoid any water or dirt penetrating the alternator via vent holes when washing the engine bay.

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

Informative inspection of alternator on the machine This inspection is of an informative nature. Only a check with measurable load using an engine bench can be considered binding.

The prerequisites of correct operation are: • Wiring integrity • Proper electrical connections on alternator, regulator and battery terminals • Sufficient drive belt tension - radial force affecting the alternator shaft via belt pull must be max 800 N along pulley’s axis.

If the alternator or regulator fails, then not only insufficient recharging but also overcharging of the battery may occur.

During normal workshop inspection of the entire power supply system (when no malfunction is expected), it is sufficient to check control voltage or how the indicator light reacts to increased RPM. When connecting the voltmeter to the B+ terminal, the regulated voltage must move within the mean RPM band ranging from 13 - 14 V.

47703722 09/09/2015

55.4 [55.301] / 3

Electrical systems - Alternator

SS12N457

1

Voltage controller The voltage converter is an integrated unit. The alternator excitation circuit is connected between the DF and D+ terminals of the controller. The controller itself is connected to the brush holder and the entire subsystem is secured to the alternator with two bolts. Its interconnection is made through three soldered circuits (B-, DF, D+) and a cable terminated with socket 6,3 to be slipped onto alternator’s D+ connector. The controller is of the throwaway type.

47703722 09/09/2015

55.4 [55.301] / 4

Electrical systems - Alternator

Alternator - Check Checking alternator-regulator set - engine bench 1.

Remove the regulator subsystem along with brush holder from the alternator.

2.

Replace (install) this subsystem with a guaranteed sound regulator.

3.

Check regulated voltage using the engine bench.

Checking alternator with no regulator - engine bench 1.

Remove the controller subsystem together with brush holder and secure a modified brush holder to the alternator.

The modified brush holder has one cable of the brush connected to the frame. The second cable of the brush has a soldered wire that has a socket for connecting to the D+ terminal. This wire continues for approx 20 cm (7.9 in) to generate short-time excitation from B+ terminal.

2.

Secure and connect the alternator to the engine bench, where a voltmeter, ammeter, ballast resistor, speedometer, and battery are connected. See the figure above.

3.

Move the alternator to approx. 1500 RPM.

4.

Excite the alternator - apply the end of the free wire connected to the brushes and D+ terminal to the B+ terminal for 2 - 3 s.

If excitation is not possible, the alternator is defective.

5.

Check alternator properties.

If no fault is found with the alternator, the regulator must be checked for malfunction.

The cause of the fault could be poor contact between the alternator frame and the vehicle frame of a faulty alternator ground connection.

47703722 09/09/2015

55.4 [55.301] / 5

Electrical systems - Alternator

Alternator - Troubleshooting Problem Charging indicator lamp is ON while engine is running

Recharging indicator lamp does not go ON following ignition turned ON.

Overcharging

Possible Cause Defective controller

Correction Replace controller

Defective rotor – earth short circuit of winding Defective stator – earth short circuit Failed diode within block Loosened soldered connections on diode pins or stator leads Indicator lamp failed

Replace rotor

Bad connection on +D terminal, or possibly on battery terminals Defective rotor – winding broken off Brush is hanging in its holder Rotor rings contaminated Defective earth connection within charging system circuit Defective controller Auxiliary diode failed

47703722 09/09/2015

55.4 [55.301] / 6

Replace stator Replace failed diode Clean, re-solder Replace lamp

Clean the connections, tighten Replace rotor Release brush, clean, or replace Clean Clean earth spots, tighten: controller - alternator, battery - body, body - engine Replace Replace

Index Electrical systems - 55 Alternator - 301 Alternator - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Alternator - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Alternator - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

47703722 09/09/2015

55.4 [55.301] / 7

47703722 09/09/2015

55.4 [55.301] / 8

Electrical systems - 55 Battery - 302

DV213

47703722 09/09/2015

55.5 [55.302] / 1

Contents Electrical systems - 55 Battery - 302

FUNCTIONAL DATA Battery Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Battery Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

47703722 09/09/2015

55.5 [55.302] / 2

Electrical systems - Battery

Battery - Static description • Handle the batteries and electrolyte with adequate care. Wear gloves and safety glasses (face shield).

• Skin stained with electrolyte: Flush immediately with water and neutralize with soap or soda. When charging, oxygen and hydrogen are released from the electrolyte on electrodes, forming explosive mixture. It is therefore forbidden to have an open flame near the battery while it is being charged. Even a spark generated when the terminal is disconnected or loosened with the charging circuit connected could cause such explosion.

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

Never disconnect the battery with the engine running.

The storage accumulator is located in the rear frame of the machine.

Commissioning The max. electrolyte temperature during charging is 40 °C (104 °F). If necessary, cool with air or water bath, lower the charging current or stop charging.

Charging current lower than that indicated in the table is beneficial to the battery. This extends charging time. When charging, ensure the filling holes are clear of any obstructions. Once charging is completed, check the electrolyte level and density. Make up and adjust density to 1.28 g/cm3 if required. Screw in the plugs. After about 2 h of degassing, rinse the battery surface with water and wipe dry.

Charging table (example) Type L100

Capacity 100 A·h

Charging 10 A

Charging symbols The battery is considered fully charged when all of its cells produce gas intensively and the electrolyte indicates 1.28 g/cm3 density in all cells. Each cell’s voltage reaches 2.5 - 2.7 V. The cumulative value for sox cells is 14.4 V at the terminal pins.

Check that the battery reaches its full state of charge over the following two hours and that the measured voltage and density values do not differ from the specified values. Discharge condition is given by 1.12 g/cm3 density.

Instantaneous state of charge is given by the values. See the following table.

Electrolyte density in g/cm3 1.28 1.23 1.20 1.15

Charge level in % 100 70 50 20

The data applies at electrolyte temperature of 27 °C (81 °F). At a temperature lowered by 15 °C (59 °F), the measured density will be higher by 0.01 g/cm3. When replenishing the electrolyte, the measured density will remain consistent after 10 - 30 min of charging, depending on the current magnitude during electrolyte intensive gassing. Fill up the level to 5 - 10 mm (0.2 - 0.4 in) above the separators using distilled water before recharging or before starting work.

Treatment while in operation A properly functioning charging system will keep the accumulator almost fully charged. The controlled voltage level moves within 13 - 14 V limits.

With the voltage level adjusted like that, check the electrolyte level after three months. During summer season, check once a week. Battery overcharging will be indicated by high electrolyte loss. Electrolyte density will lower with insufficient charging. The self-discharging current of the battery is about 1 % of its capacity each day.

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

Keep the accumulator batteries clean and properly secured; the fixing device shall not cripple the accumulator block.

Battery terminals must be properly tightened.

47703722 09/09/2015

55.5 [55.302] / 3

Electrical systems - Battery

Electrolyte aerosol forms sulfates across the surface of the terminals’ metal parts. Clean off such sulfates. Protect cleaned metal parts with a thin layer of preservation jelly or oil.

NOTE: Recharge the batteries following two months of decommissioning.

47703722 09/09/2015

55.5 [55.302] / 4

Electrical systems - Battery

Battery - Remove 1. Remove the battery terminals.

SS12N634

1

SS12N635

2

2. Remove the battery holder.

3. Remove the battery.

47703722 09/09/2015

55.5 [55.302] / 5

Electrical systems - Battery

Battery - Install 1. Install the battery.

2. Install the battery holder.

SS12N635

1

SS12N634

2

3. Install the battery terminals.

47703722 09/09/2015

55.5 [55.302] / 6

Index Electrical systems - 55 Battery - 302 Battery - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Battery - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Battery - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

47703722 09/09/2015

55.5 [55.302] / 7

47703722 09/09/2015

55.5 [55.302] / 8

Electrical systems - 55 Warning indicators, alarms, and instruments - 408

DV213

47703722 09/09/2015

55.6 [55.408] / 1

Contents Electrical systems - 55 Warning indicators, alarms, and instruments - 408

FUNCTIONAL DATA Instrument cluster Fault code index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Operator presence switch Operator seat - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Instrument cluster Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

DIAGNOSTIC Instrument cluster Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

47703722 09/09/2015

55.6 [55.408] / 2

Electrical systems - Warning indicators, alarms, and instruments

Instrument cluster - Fault code index All fault codes should be diagnosed by an authorized engine dealer. Please contact your local engine dealer for assistance. Below is the list of fault codes for this machine. Do not attempt to diagnose these fault codes without the proper training and tools.

Fault code list Fault code 115

Lamp color Red

122

Amber

123

Amber

125

Amber

131

Red

132

Red

133

Red

134

Red

135

Amber

141

Amber

143

Amber

144

Amber

145

Amber

146

Amber

147

Red

148

Red

151

Red

153

Amber

154

Amber

155

Red

187

Amber

193

Amber

194

Amber

195

Amber

Description Definition System diagnostic code # 2 Engine speed/position sensor circuit lost both of two signals from the magnetic pickup sensor - data erratic, intermittent, or incorrect Boost pressure Intake manifold pressure sensor circuit - voltage above normal, or shorted to high source Boost pressure Intake manifold pressure sensor circuit - voltage below normal, or shorted to low source Engine intake manifold #1 Intake manifold 1 pressure - data valid but below pressure normal operating range - moderately severe level Accelerator pedal position Accelerator pedal or lever position sensor circuit voltage above normal, or shorted to high source Accelerator pedal position Accelerator pedal or lever position sensor circuit voltage below normal, or shorted to low source Remote accelerator Remote accelerator pedal or lever position sensor circuit - voltage above normal, or shorted to high source Remote accelerator Remote accelerator pedal or lever position sensor circuit - voltage below normal, or shorted to low source Engine oil pressure Oil pressure sensor circuit - voltage above normal, or shorted to high source Engine oil pressure Oil pressure sensor circuit - voltage below normal, or shorted to low source Engine oil pressure Oil pressure low - data valid but below normal operational range - moderately severe level Engine coolant temperature Coolant temperature sensor circuit - voltage above normal, or shorted to high source Engine coolant temperature Coolant temperature sensor circuit - voltage below normal, or shorted to low source Engine coolant temperature Coolant temperature high - data valid but above normal operational range - moderately severe level Accelerator pedal position Accelerator pedal or lever position sensor circuit abnormal frequency, pulse width, or period Accelerator pedal position accelerator pedal or lever position sensor circuit abnormal frequency, pulse width, or period Engine coolant temperature Coolant temperature low - data valid but above normal operational range - most severe level Intake manifold #1 Intake manifold air temperature sensor circuit temperature Voltage Above Normal, or Shorted to High Source Intake manifold #1 Intake manifold air temperature sensor circuit temperature voltage below normal, or shorted to low source Intake manifold #1 Intake manifold air temperature high – data valid temperature but above normal operational range - most severe 5 volts DC supply Sensor supply voltage #2 circuit - voltage below normal, or shorted to low source Cruise control Cruise control (resistive) signal circuit - voltage above normal, or shorted to high source Cruise control Cruise control (resistive) signal circuit - voltage below normal, or shorted to low source Coolant level Coolant level sensor circuit - voltage above normal, or shorted to high source 47703722 09/09/2015

55.6 [55.408] / 3

Electrical systems - Warning indicators, alarms, and instruments

196

Amber

Coolant level

197

Amber

Coolant level

221

Amber

Barometric pressure

222

Amber

Barometric pressure

227

Amber

5 volts DC supply

234

Red

Engine speed

235

Red

Coolant level

237

Amber

External speed input

238

Amber

System diagnostic code # 1

239

Amber

System diagnostic code #2

241

Amber

Wheel-based vehicle speed

242

Amber

Wheel-based vehicle speed

244

Amber

Red stop lamp

245

Amber

271

Amber

272

Amber

281

Amber

Fan clutch output device driver Fuel pump pressurizing assembly #1 Fuel pump pressurizing assembly #1 Fuel pump pressurizing assembly #1

285

Amber

SAE J1939 datalink

286

Amber

SAE J1939 datalink

287

Red

Accelerator pedal position

288

Red

Remote accelerator

292

Red

Auxiliary temperature 1

293

Amber

OEM temperature

294

Amber

OEM temperature

295

Amber

Barometric pressure

296

Red

Auxiliary pressure

297

Amber

Auxiliary pressure

298

Amber

Auxiliary pressure

Coolant level sensor circuit - voltage below normal, or shorted to low source Coolant level - data valid but below normal operational range - moderately severe level Barometric pressure sensor circuit - voltage above normal, or shorted to high source Barometric pressure sensor circuit - voltage below normal, or shorted to low source Sensor supply voltage #2 circuit - voltage above normal, or shorted to high source Engine speed high - data valid but above normal operational range - most severe level Coolant level low - data valid but below normal operational range - most severe level External speed input (multiple unit synchronization) - data erratic, intermittent, or incorrect Sensor supply voltage #3 circuit - voltage below normal, or shorted to low source Sensor supply voltage #3 circuit - voltage above normal, or shorted to high source Vehicle speed sensor circuit - data erratic, intermittent, or incorrect Vehicle speed sensor circuit tampering has been detected - abnormal rate of change Red stop lamp driver circuit - voltage below normal, or shorted to low source Fan control circuit - voltage below normal, or shorted to low source High fuel pressure solenoid valve circuit - voltage below normal, or shorted to low source High fuel pressure solenoid valve circuit - voltage above normal, or shorted to high source High fuel pressure solenoid valve #1 - mechanical system not responding properly or out of adjustment SAE J1939 multiplexing PGN timeout error abnormal update rate SAE J1939 multiplexing configuration error – out of calibration SAE J1939 multiplexing accelerator pedal or lever sensor system error - received network data in error SAE J1939 multiplexing remote accelerator pedal or lever data error - received network data in error Auxiliary temperature sensor input 1 - special instructions Auxiliary temperature sensor input # 1 circuit voltage above normal, or shorted to high source Auxiliary temperature sensor input # 1 circuit voltage below normal, or shorted to low source Barometric pressure sensor circuit - data erratic, intermittent, or incorrect Auxiliary pressure sensor input 1 - special instructions Auxiliary pressure sensor input # 2 circuit - voltage above normal, or shorted to high source Auxiliary pressure sensor input # 2 circuit - voltage below normal, or shorted to low source

47703722 09/09/2015

55.6 [55.408] / 4

Electrical systems - Warning indicators, alarms, and instruments

322 323 324 325 331 332 343 349

351 352 386 415 418 422 426 428 429 431 432 435 441 442 449 451 452 488

489

497

Amber

Injector cylinder #01

Injector solenoid cylinder #1 circuit - current below normal, or open circuit Amber Injector cylinder #05 Injector solenoid cylinder #5 circuit - current below normal, or open circuit Amber Injector cylinder #03 Injector solenoid cylinder #3 circuit - current below normal, or open circuit Amber Injector cylinder #06 Injector solenoid cylinder #6 circuit - current below normal, or open circuit Amber Injector cylinder #02 Injector solenoid cylinder #2 circuit - current below normal, or open circuit Amber Injector cylinder #04 Injector solenoid cylinder #4 circuit - current below normal, or open circuit Amber Engine control module warning internal hardware Controller #1 failure - bad intelligent device or component Amber Transmission output shaft Transmission output shaft speed - data valid but speed above normal operational range - moderately severe level Amber Injector power supply - bad intelligent device or Controller #1 component Amber 5 Volts DC supply Sensor supply voltage #1 circuit - voltage below normal, or shorted to low source Amber 5 Volts DC supply Sensor supply voltage #1 circuit - voltage above normal, or shorted to high source Red Engine oil pressure Oil pressure low - data valid but below normal operational range - most severe level Amber/ Blinking Water in fuel indicator Water in fuel indicator high - data valid but above normal operational range – least severe level Amber Coolant level Coolant level - data erratic, intermittent, or incorrect Amber Not available J1939 network #1 - data erratic, intermittent or incorrect Amber Water in fuel indicator Water in fuel sensor circuit - voltage above normal, or shorted to high source Amber Water in fuel indicator Water in fuel sensor circuit - voltage below normal, or shorted to low source Amber Accelerator pedal low idle Accelerator pedal or lever idle validation circuit switch data erratic, intermittent, or incorrect Red Accelerator pedal low idle Accelerator pedal or lever idle validation circuit switch out of calibration Amber Engine oil pressure Oil pressure sensor circuit - data erratic, intermittent, or incorrect Amber Electrical potential (voltage) Battery #1 voltage low - data valid but below normal operational range – moderately severe level Amber Electrical potential (voltage) Battery #1 voltage high - data valid but above normal operational range - moderately severe level Red Injector metering rail 1 Fuel pressure high - data valid but above normal pressure operational range - moderately severe level Amber Injector metering rail 1 Injector metering rail #1 pressure sensor circuit pressure voltage above normal, or shorted to high source Amber Injector metering rail 1 Injector metering rail #1 pressure sensor circuit pressure voltage below normal, or shorted to low source Amber Intake manifold Intake manifold 1 temperature - data valid but above normal operational range - moderately severe level Amber Transmission output shaft Transmission output shaft speed - data valid but speed below normal operational range - moderately severe level Amber Multiple unit synchronization switch circuit - data Switch circuit erratic, intermittent, or incorrect

47703722 09/09/2015

55.6 [55.408] / 5

Electrical systems - Warning indicators, alarms, and instruments

515 516 523 527 528 529 553

555 556 559

584 595 599 649 687 689 691

697 698 731

769 771 778 779 951 952 953 1117

Amber

Not available

Sensor supply 6 circuit - voltage above normal, or shorted to high source Amber Not available Sensor supply 6 circuit - voltage below normal, or shorted to low source Amber System diagnostic code # 1 OEM intermediate (PTO) speed switch validation data erratic, intermittent, or incorrect Amber Circuit - voltage Auxiliary input/output 2 circuit - voltage above normal, or shorted to high source Amber Auxiliary constrained operation curve validation Switch - data switch - data erratic, intermittent, or incorrect Amber Circuit - voltage Auxiliary input/output 3 circuit - voltage above normal, or shorted to high source Amber Injector metering rail 1 Injector metering rail #1 pressure high – data valid pressure but above normal operational range - moderately severe level Amber Not available Crankcase pressure - data valid but above normal operating range - moderately severe level Red Not available Crankcase pressure - data valid but above normal operating range - moderately severe level Amber Injector metering rail 1 Injector metering rail #1 pressure low – data valid pressure but below normal operational range - moderately severe level Amber Starter solenoid lockout Starter relay driver circuit - voltage above normal, relay driver circuit or shorted to high source Amber Turbocharger 1 speed Turbocharger #1 speed high - data valid but above normal operational range - moderately severe level Red Engine external protection Auxiliary commanded dual output shutdown input special instructions Amber/ Blinking Engine oil change interval Change lubricating oil and filter - condition exists Amber Turbocharger 1 speed Turbocharger #1 speed low - data valid but below normal operational range - moderately severe level Amber Engine speed Primary engine speed sensor error - data erratic, intermittent, or incorrect Amber Turbocharger #1compres- Turbocharger 1 compressor inlet temperature circuit- voltage above normal, or shorted to high sor inlet temperature source Amber Sensor circuit - voltage ECM internal temperature sensor circuit - voltage above normal, or shorted to high source Amber Sensor circuit - voltage ECM internal temperature sensor circuit - voltage below normal, or shorted to low source Amber Engine speed sensor #2 Engine speed/position #2 mechanical misalignment between camshaft and crankshaft sensors mechanical system not responding properly or out of adjustment Amber Not available Brake switch circuit - voltage above normal, or shorted to high source Amber Not available Brake switch circuit - voltage below normal, or shorted to low source Amber Engine speed sensor #2 Engine speed sensor (camshaft) error - data erratic, intermittent, or incorrect Amber Auxiliary equipment sensor Warning auxiliary equipment sensor input # 3 input (OEM switch) - root cause not known None Not available Cylinder power imbalance between cylinders - data erratic, intermittent or incorrect Amber Not available Reserved for temporary use - condition exists Amber Not available Reserved for temporary use - condition exists None Power supply Power lost with ignition on - data erratic, intermittent, or incorrect

47703722 09/09/2015

55.6 [55.408] / 6

Electrical systems - Warning indicators, alarms, and instruments

1239

Amber

Accelerator pedal position

1241

Amber

Not available

1242

Red

Accelerator pedal position

1381

Amber/ Blinking Not available

1663

Amber

Not available

1664

Amber

Not available

1665

Amber

Not available

1666

Amber

Not available

1667

Amber

Not available

1674

Amber

Not available

1675

Amber

Not available

1676

Amber

Not available

1691

Amber

Not available

1695

Amber

Not available

1696

Amber

Not available

1843

Amber

Not available

1844

Amber

Not available

1847 1852

Red Amber

Not available Water in fuel indicator

1866

Amber

Not available

1876

Amber

Not available

1877

Amber

Not available

1878

Amber

Not available

1879

Amber

Not available

1881

Amber

Not available

1883

Amber

Not available

1896 1911

Amber Amber

Not available Injector metering rail

Accelerator pedal or lever position sensor 2 circuit - voltage above normal, or shorted to high source Accelerator pedal or lever position sensor 2 circuit - voltage below normal, or shorted to low source Accelerator pedal or lever position sensor 1 and 2 data erratic, intermittent, or incorrect Auxiliary temperature sensor input 1 - special instructions After-treatment exhaust gas temperature 1 swapped - out of calibration After-treatment diesel oxidation catalyst missing condition exists After-treatment exhaust gas temperature 1 circuit voltage below normal, or shorted to low source After-treatment exhaust gas temperature 1 circuit voltage below normal, or shorted to low source After-treatment exhaust gas temperature 1 - data erratic, intermittent or incorrect After-treatment exhaust gas temperature 2 circuit voltage below normal, or shorted to low source After-treatment exhaust gas temperature 2 circuit voltage below normal, or shorted to low source After-treatment exhaust gas temperature 2 - data erratic, intermittent or incorrect After-treatment diesel oxidation catalyst system - data valid but below normal operating range moderately severe level Sensor supply 5 - voltage above normal, or shorted to high source Sensor supply 5 - voltage below normal, or shorted to low source Crankcase pressure circuit - voltage above normal, or shorted to high source Crankcase pressure circuit - below normal, or shorted to low source Engine coolant temperature - special instructions Water in fuel indicator - data valid but above normal operational range - moderately severe level Exhaust Gas Recirculation (EGR) valve delta pressure - data erratic, intermittent or incorrect After-treatment exhaust gas temperature 3 circuit voltage above normal, or shorted to high source After-treatment exhaust gas temperature 3 circuit voltage below normal, or shorted to low source After-treatment exhaust gas temperature 3 - data erratic, intermittent or incorrect After-treatment particulate filter differential pressure sensor circuit - voltage above normal, or shorted to high source After-treatment particulate filter differential pressure sensor circuit - voltage below normal, or shorted to low source After-treatment particulate filter differential pressure sensor - data erratic, intermittent or incorrect EGR valve controller - out of calibration Injector metering rail 1 pressure - data valid but above normal operational range - most severe level

47703722 09/09/2015

55.6 [55.408] / 7

Electrical systems - Warning indicators, alarms, and instruments

1921

1922

1938

1939 1941 1942 1943 1962

1968

1972

1974 1981 1993 2185 2186 2195 2249 2263 2264 2265 2266 2272 2273

2274

2288

Amber

Not available

After-treatment particulate filter differential pressure - data valid but above normal operating range moderately severe level Red Not available After-treatment particulate filter differential pressure - data valid but above normal operational range most severe level Amber Not available ECU power output supply voltage 1 - data valid but below normal operating range - moderately severe level Amber Not available ECU power output supply voltage 1 - voltage above normal, or shorted to high source Amber Not available ECU power output supply voltage 1 - voltage below normal, or shorted to low source Amber Not available Crankcase pressure - data erratic, intermittent or incorrect None Not available Ambient air density - data valid but below normal operating range - least severe level Amber Not available VGT/VFT actuator driver over temperature (calculated) - data valid but above normal operating range - least severe level Amber Not available After-treatment exhaust gas temperature 2 Data Valid But Above Normal Operating Range Moderately Severe Level Amber Not available After-treatment exhaust gas temperature 3 data valid but above normal operating range moderately severe level Amber/ Blinking Not available Crankcase pressure - data valid but above normal operating range - least severe level Amber Not available After-treatment diesel particulate filter system data valid but above normal operating range Amber Not available After-treatment diesel particulate filter missing condition exists Not available Not available Sensor supply 4 circuit - voltage above normal, or shorted to high source Amber System diagnostic code # 1 Sensor supply 4 circuit - voltage below normal, or shorted to low source Not available Not available Auxiliary equipment sensor input 3 engine protection critical - special instructions Amber Injector metering rail 1 Injector metering rail 1 pressure - data valid but pressure below normal operational range - most severe level Amber Battery temperature Battery temperature - data valid but above normal operational range - moderately severe level Amber Battery temperature Battery temperature - data valid but below normal operational range - moderately severe level Amber Electric lift pump for engine Fuel priming pump control signal circuit - voltage above normal, or shorted to high source fuel Amber Electric lift pump for engine Fuel priming pump control signal circuit - Voltage Below Normal, or Shorted to Low Source fuel Amber Not available EGR valve position circuit - voltage below normal, or shorted to low source Amber Not available Exhaust Gas Recirculation (EGR) valve delta pressure sensor circuit - voltage above normal, or shorted to high source Amber Not available Exhaust Gas Recirculation (EGR) valve delta pressure sensor circuit - voltage below normal, or shorted to low source None Not available Turbocharger 1 speed - data valid but above normal operating range - least severe level

47703722 09/09/2015

55.6 [55.408] / 8

Electrical systems - Warning indicators, alarms, and instruments

2292

Amber

Fuel inlet meter device

2293

Amber

Fuel inlet meter device

2311 2321

Amber None

Fuel control valve #1 Engine speed

2322

None

Engine speed sensor #2

2346

None

System diagnostic code #1

2349

Amber

Not available

2351

Amber

Not available

2353

Not available

Not available

2357

Amber

Not Available

2363

Amber

2365

Amber

Engine compression brake output # 2 Engine brake output # 3

2367

Amber

2368

Amber

Engine compression brake output # 2 Engine brake output # 3

2372

Not Available

Not Available

2373

Amber

Exhaust gas pressure

2374

Amber

Exhaust gas pressure

2375

Amber

Exhaust Gas Recirculation (EGR) temperature

2376

Amber

Exhaust Gas Recirculation (EGR) temperature

2377

Amber

2387

Amber

Fan clutch output device driver Not available

2448

Amber/ Blinking Coolant level

2449 2468

Red Not available

Not available Not available

2554

Amber

Not Available

2555

Amber

Inlet air heater driver #1

2556

Amber

Inlet air heater driver #1

Fuel inlet meter device - data valid but above normal operational range - moderately severe level Fuel inlet meter device flow demand lower than expected - data valid but below normal operational range - moderately severe level Fueling actuator #1 circuit error – condition exists Engine speed/position sensor #1 - data erratic, intermittent, or incorrect Engine speed/position sensor #2 - data erratic, intermittent, or incorrect Turbocharger turbine inlet temperature (calculated) - data valid but above normal operational range least severe level EGR valve control circuit - current below normal or open circuit EGR valve control circuit - voltage below normal, or shorted to low source EGR valve control circuit - current above normal or grounded circuit EGR valve control circuit - mechanical system not responding or out of adjustment Engine brake actuator driver output 2 circuit voltage below normal, or shorted to low source Engine brake actuator driver output 3 circuit voltage below normal, or shorted to low source Engine brake actuator driver output 2 circuit voltage above normal, or shorted to high source Engine brake actuator driver 3 circuit - voltage above normal, or shorted to high source Fuel filter differential pressure - data valid but above normal operating range - moderately severe level Exhaust gas pressure sensor circuit - voltage above normal, or shorted to high source Exhaust gas pressure sensor circuit - voltage below normal, or shorted to low source Exhaust Gas Recirculation (EGR) temperature sensor circuit - voltage above normal, or shorted to high source Exhaust Gas Recirculation (EGR) temperature sensor circuit - voltage below normal, or shorted to low source Fan control circuit - voltage above normal, or shorted to high source VGT actuator driver circuit (motor) - mechanical system not responding or out of adjustment Coolant level - data valid but below normal operating range - least severe level VGT actuator controller - out of calibration Engine crankshaft speed/position - data valid but above normal operating range - moderately severe level Exhaust gas pressure - data erratic, intermittent or incorrect Intake air heater #1 circuit - voltage above normal, or shorted to high source Intake air heater #1 circuit - voltage below normal, or shorted to low source

47703722 09/09/2015

55.6 [55.408] / 9

Electrical systems - Warning indicators, alarms, and instruments

2557

Amber

2558

Amber

2571

Amber

2572

Amber

2634

Red

2635 2636 2637

Red Red None

2638

None

2639

None

2646 2659 2699

Amber None Amber

2728

None

2742

None

2743

Amber

2754

Amber

2764

Amber

2765 2774

None Amber

2777

None

2778

Amber

2789

Amber

2961

None

2962

Amber

2973

Amber

2998 3133

Amber Amber

Not available

Auxiliary PWM driver #1 - voltage above normal, or shorted to high source Not available Auxiliary PWM driver #1 - voltage below normal, or shorted to low source Not available Engine charge air cooler outlet temperature voltage above normal, or shorted to high source Not available Engine charge air cooler outlet temperature voltage below normal, or shorted to low source Not available VGT actuator controller - bad intelligent device or component Not available VGT actuator driver circuit - condition exists Not available VGT actuator driver circuit - abnormal update rate Not available After-treatment diesel oxidation catalyst face plugged - root cause not known Not available After-treatment diesel oxidation catalyst system data valid but below normal operating range - least severe level Not available After-treatment particulate filter differential pressure - data valid but above normal operating range least severe level Not available Engine coolant temperature - condition exists Not available Engine coolant temperature - condition exists Not available Crankcase depression valve - mechanical system not responding or out of adjustment Not available After-treatment fuel injector 1 - data valid but above normal operating range - moderately severe level Not available After-treatment exhaust gas temperature 2 - data valid but below normal operating range - least severe level Not available After-treatment exhaust gas temperature 2 data valid but below normal operating range moderately severe level Not available Engine particulate trap inlet pressure - data valid but above normal operating range - moderately severe level Not available Exhaust gas pressure - data valid but above normal operating range - moderately severe level Not available Engine injector bank 1 barcodes - out of calibration Reserved for assignment Engine Exhaust Gas Recirculation (EGR) system condition exists Particulate trap active regeneration inhibited due to Reserved for assignment inhibit switch - condition exists Reserved for assignment After-treatment fuel rate - data valid but above normal operating range - moderately severe level Not available Engine coolant temperature - data valid but below normal operating range - moderately severe level Engine intake valve actuator Exhaust Gas Recirculation (EGR) temperature #12 data valid but above normal operating range - least severe level Engine intake valve actuator Exhaust Gas Recirculation (EGR) temperature #13 - data valid but above normal operating range moderately severe level Boost pressure Intake manifold pressure sensor circuit - data erratic, intermittent, or incorrect Not available Engine torque limit feature - special instructions Not available After-treatment diesel particulate filter outlet pressure sensor circuit - voltage above normal, or shorted to high source

47703722 09/09/2015

55.6 [55.408] / 10

Electrical systems - Warning indicators, alarms, and instruments

3134

Amber

Not available

3135

Amber

Not available

3136

Amber

Not available

3137

Amber

Not available

3139

Amber

Not available

3141

Amber

Not available

3168

Amber

Not available

3186

Amber

Not available

3213

Amber

Not available

3222

Amber

Not available

3251

Red

Not available

3253

Red

Not available

3254

Amber

Not available

3295

Amber

Not available

3296

Amber

Not available

3311

Red

3312

Red

3313

Amber

After-treatment 1 diesel particulate filter intake gas temperature After-treatment 1 diesel particulate filter outlet gas temperature Not available

3314

Amber

Not available

3315

Amber

Not available

3316

Amber

Not available

3317

Amber

Not available

After-treatment diesel particulate filter outlet pressure sensor circuit - voltage below normal, or shorted to low source After-treatment diesel particulate filter outlet pressure - data erratic, intermittent or incorrect Engine Exhaust Gas Recirculation (EGR) outlet pressure sensor circuit - above normal, or shorted to high source Engine Exhaust Gas Recirculation (EGR) outlet pressure sensor circuit - voltage below normal, or shorted to low source Engine air shutoff circuit - voltage above normal, or shorted to high source Engine air shutoff circuit - voltage below normal, or shorted to low source After-treatment diesel particulate filter system data valid but above normal operating range moderately severe level Tachometer output shaft speed - abnormal update rate Tachometer output shaft speed - received network data in error Glow plug module - bad intelligent device or component After-treatment 1 diesel oxidation catalyst intake temperature - data valid but above normal operating range - moderately severe level After-treatment 1 diesel particulate filter intake temperature - data valid but above normal operating range - moderately severe level After-treatment 1 diesel particulate filter intake temperature - data valid but above normal operating range - least severe level Engine Exhaust Gas Recirculation (EGR) mixer inlet temperature sensor circuit - voltage above normal, or shorted to high source Engine Exhaust Gas Recirculation (EGR) mixer inlet temperature sensor circuit - voltage below normal, or shorted to low source After-treatment diesel particulate filter intake gas temperature - data valid but above normal operational range - most severe level After-treatment diesel particulate filter outlet gas temperature - data valid but above normal operational range - most severe level After-treatment 1 diesel oxidation catalyst intake temperature sensor circuit - voltage below normal, or shorted to low source After-treatment 1 diesel oxidation catalyst intake temperature sensor circuit - voltage above normal, or shorted to high source After-treatment 1 diesel oxidation catalyst intake temperature sensor circuit - data erratic, intermittent or incorrect After-treatment 1 diesel particulate filter intake temperature sensor circuit - voltage below normal, or shorted to low source After-treatment 1 diesel particulate filter intake temperature sensor circuit - voltage above normal, or shorted to high source

47703722 09/09/2015

55.6 [55.408] / 11

Electrical systems - Warning indicators, alarms, and instruments

3318

Amber

Not available

3325

Amber

Not available

3326

Red

Not available

3328

Amber

Not available

3329

Amber

Message selection control

3331

Amber

Not available

3369

Amber

Not available

3371

Amber

Not available

3372

Amber

Not available

3373

Amber

Not available

3377

Amber

Not available

3712

Red

Not available

3727

NA

Not available

3737

NA

Not available

3918

Amber

Not available

3921

Amber

Not available

3922

Amber

Not available

3923

Amber

Not available

3924 3925

Amber Amber

Not available Not available

3927

Amber

Not available

3928

Amber

Not available

After-treatment 1 diesel particulate filter intake temperature - data erratic, intermittent or incorrect After-treatment 1 diesel oxidation catalyst intake temperature swapped - out of calibration SAE J1939 multiplexed accelerator pedal or lever sensor system - abnormal update rate Transmission output shaft speed - abnormal update rate J1939 Network #2 - data erratic, intermittent or incorrect J1939 Network #3 - data erratic, intermittent or incorrect Turbocharger 1 compressor inlet temperature sensor - abnormal update rate Turbocharger 1 compressor inlet temperature sensor - received network data In error Turbocharger 1 compressor inlet pressure abnormal update rate Turbocharger 1 compressor inlet pressure received network data In error Engine crankcase ventilation hose disconnected condition exists After-treatment SCR operator inducement - data valid but above normal operational range - most severe level High pressure common rail fuel pressure relief valve - mechanical system not responding or out of adjustment Engine starter mode Over-crank protection condition exists Engine turbocharger wastegate Actuator - Out of Calibration Engine turbocharger waste gate actuator mechanical system not responding or out of adjustment Engine turbocharger waste gate actuator - current below normal or open circuit Engine turbocharger waste gate actuator - current above normal or grounded circuit Utility reverse kW fault - condition exists Engine turbocharger waste gate actuator 1 position - data erratic, intermittent or incorrect Engine turbocharger waste gate actuator - root cause not known Engine turbocharger waste gate actuator condition exists

47703722 09/09/2015

55.6 [55.408] / 12

Electrical systems - Warning indicators, alarms, and instruments

Operator seat - Replace 1. Remove the bolts and remove the seat upholstery.

SS12M168

1

SS12M169

2

SS12M170

3

SS12M171

4

2. Fold up the seat.

3. Drill out the rivets and replace the seat switch.

47703722 09/09/2015

55.6 [55.408] / 13

Electrical systems - Warning indicators, alarms, and instruments

Instrument cluster - Replace 1. Turn OFF the battery master switch before replacing the instrument.

2. Turn it ON after replacement.

SS12N055

1

SS12N056

2

SS12N057

3

3. Remove the screws along the perimeter of the instrument board.

4. Open the instrument board.

5. Unplug the connector from the socket (A).

6. Remove the fixing nut (B).

7. Connect the new instrument.

8. Reassemble the instrument board.

47703722 09/09/2015

55.6 [55.408] / 14

Electrical systems - Warning indicators, alarms, and instruments

Instrument cluster - Adjust If the multifunctional display is replaced, adjust the following parameters: • Fuel consumption (FUEL RATE) • 4 UP DISPLAY

Adjust fuel consumption 1. When the ignition key is turned ON, the four-parameter display will be shown.

2. Press MENU to enter the main menu.

SS12N447

1

SS12N448

2

SS12N475

3

3. Move the cursor (1) to SETUP 1 - UP DISPLAY. 4. Confirm with Enter (2).

5. Move the cursor (1) to CUSTOM SETUP. 6. Confirm with Enter (2).

47703722 09/09/2015

55.6 [55.408] / 15

Electrical systems - Warning indicators, alarms, and instruments

7. Move the cursor (1) to FUEL RATE. 8. Confirm with Enter (2) (parameter no. 7 will be displayed).

9. Click step by step using the MENU button (3).

SS12N450

4

SS12N456

5

SS12N451

6

SS12N452

7

10. On four-parameter display, change parameters as follows:

11. Change ENG HOURS to FUEL RATE parameter in four-parameter display (bottom right).

12. Press the MENU button.

13. After entering the main menu, use the left-hand (righthand) cursor (1) to select SETUP 4 - UP DISPLAY. 14. Confirm with Enter (2).

47703722 09/09/2015

55.6 [55.408] / 16

Electrical systems - Warning indicators, alarms, and instruments

15. Use the left-hand cursor (1) to select CUSTOM SETUP. 16. Confirm with Enter (2).

SS12N475

8

SS12N453

9

17. In four-parameter display, use the cursor (1) to select ENG HOURS. 18. Confirm with Enter (2).

19. In the parameter menu, use the cursor (1) to select FUEL RATE (no. 4 will be displayed with the item).

20. Confirm with Enter (2).

21. Press the MENU button (3) to return to four-parameter display.

SS12N454

10

SS12N455

11

22. The FUEL RATE has now been adjusted (bottom right).

NOTICE: To store the data in the computer memory, turn OFF the battery master switch only after thirty seconds following multifunctional instrument setup completion.

The machine manufacturer does not permit the modification of set parameters, other than those mentioned above when the multifunctional instrument or fuel gauge is replaced!

47703722 09/09/2015

55.6 [55.408] / 17

Electrical systems - Warning indicators, alarms, and instruments

Instrument cluster - Troubleshooting Problem “WAIT TO START PREHEATING” is displayed ”CANBUS FAILURE” is displayed

“TIMEOUT ECU NOT RESPONDING” is displayed

Possible Cause Correction The Engine Control Unit (ECU) is telling the When the ECU decides the engine is ready operator to wait before starting the engine. for operation, this screen will no longer appear on the multifunctional display and the operator can start the engine.

The multifunctional display has not re- 1. Search for additional trouble codes within the system. ceived any valid J1939 CAN messages for at least 30 s.

2. Check the CAN Bus circuit for opens, shorts, and high resistance.

The multifunctional display sent a request 1. Search for additional trouble codes within the system. to the ECU for stored fault code (DM2) information and the ECU did not respond to 2. Check the CAN Bus circuit for opens, the request. shorts, and high resistance.

3. This message could indicate that the ECU may not support the stored fault code (DM2) functionality over the CAN Bus. ”NO STORED CODES” is The multifunctional display sent a request No action needed. The system is working displayed to the ECU for stored fault code (DM2) in- as designed. formation and the ECU responded. There are zero stored codes. ”NO GAUGE DATA” is The multifunctional display has no record of 1. Search for additional trouble codes displayed gauges connected to the RS485 bus. within the system.

2. Check the CAN Bus circuit for opens, shorts, and high resistance.

The ECU is transmitting a message that it Change the parameter on the display does not support this parameter.

“NOT SUPPORTED” is displayed in place of a parameter value ”NO DATA” is displayed in The multifunctional display has not re- 1. Scan for fault codes place of a parameter value ceived data for the selected parameter for 2. Check the circuit related to the parameat least 5 s. ter The ECU is transmitting a message that 1. Scan for fault codes ”DATA ERROR” is there is a data error with this parameter. displayed in place of 2. Check the circuit related to the paramea parameter value ter The fuel level has been selected for display, and analog input has been set to fuel level, but no fuel sensor has been connected to the analog input.

One of the 4-UP quadrants No parameter has been selected for display is empty in this quadrant.

The display is not The LCD contrast may have been over or readable, very dim, or under adjusted. very dark

47703722 09/09/2015

55.6 [55.408] / 18

1. Check the functionality of the fuel level sensor.

2. Check the circuit of the fuel level sensor.

Select a parameter to be displayed in the quadrant.

Press and hold the menu button for approximately 5 s. This will reset the LCD contrast setting to factory default.

Index Electrical systems - 55 Warning indicators, alarms, and instruments - 408 Instrument cluster - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Instrument cluster - Fault code index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Instrument cluster - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Instrument cluster - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Operator seat - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

47703722 09/09/2015

55.6 [55.408] / 19

47703722 09/09/2015

55.6 [55.408] / 20

Electrical systems - 55 Hydrostatic drive control system - 019

DV213

47703722 09/09/2015

55.7 [55.019] / 1

Contents Electrical systems - 55 Hydrostatic drive control system - 019

SERVICE Hydrostatic drive control sensors Adjust the pulse sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

47703722 09/09/2015

55.7 [55.019] / 2

Electrical systems - Hydrostatic drive control system

Hydrostatic drive control sensors - Adjust the pulse sensors NOTE: Always adjust the pulse sensors again when replacing the sensor for the travel hydrostatic motor (see Travel motor - Remove (35.353).

Pulse sensor of KPPF 156 type: 1. Use a 1/2 inch wrench (1) to adjust the sensor 2. Use an 11/16 inch wrench (2) to tighten the sensor

SS12K550

1

SS12K551

2

SS12M037

3

SS12K553

4

Location of pulse sensor on the machine: NOTE: The sensor is installed on the right-hand side on the front drum and on the left-hand side on the rear drum.

Observe the following procedure to adjust the sensors: 1. Install pulse sensor (1) down to the stop in the hydrostatic motor for vibration and travel until it touches the magnetic ring (2).

47703722 09/09/2015

55.7 [55.019] / 3

Electrical systems - Hydrostatic drive control system

2. Rotate the pulse sensor by 1/2 - 1 turn in the rearward direction so that there is clearance of maximum 1.52 mm (0.060 in) between the pulse sensor and magnetic ring.

SS12K552

Pos. A B

Designation Speed ring Air gap to be 1.524 mm (0.060 in) maximum

5

Pos. H I

C

M12x1-6G THD

J

D E

61.21 mm (2.41 in) 50.8 mm (2.0 in)

K L

F

26.4 mm (1.0 in)

M

G

16.26 mm (0.64 in)

Designation Keyway Pin 1 Power + Pin 4 Ground 12.7 mm (0.5 in) Spanner Pin 3 Speed Pin 2 Direction

3. Tighten the sensor by the nut with wrench (2) to 13 N·m (10 lb ft) torque.

4. When tightened, check sensor position as per the hydrostatic motor axis (see Figure 5).

5. Adjust with wrench (1).

SS12M038

47703722 09/09/2015

55.7 [55.019] / 4

6

Index Electrical systems - 55 Hydrostatic drive control system - 019 Hydrostatic drive control sensors - Adjust the pulse sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

47703722 09/09/2015

55.7 [55.019] / 5

47703722 09/09/2015

55.7 [55.019] / 6

Electrical systems - 55 Heating, Ventilation, and Air-Conditioning (HVAC) control system 050

DV213

47703722 09/09/2015

55.8 [55.050] / 1

Contents Electrical systems - 55 Heating, Ventilation, and Air-Conditioning (HVAC) control system - 050

FUNCTIONAL DATA Blower Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Blower Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

47703722 09/09/2015

55.8 [55.050] / 2

Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system

Blower - Component identification

SS13G119

Pos. 1 2 3 4 5

Designation Fan housing Ventilator Plate Seal Seal

1

Pos. 7 8 9 10 11

47703722 09/09/2015

55.8 [55.050] / 3

Designation Terminal sleeve Nut Countersunk screw Hexagon head screw Lock washer

Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system

SS13J007

2

47703722 09/09/2015

55.8 [55.050] / 4

Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system

Pos. 1 12 22 26 38 41 42 48 72 74 91 98 101 102 105 110 112 114 116

Designation Cabin Front cover Bolt Bracket Cover Cover Nut Washer Pull rod Plate Bolt Crank Handle Cover Ventilation nozzle Seal Strut Band Rubber profile

Pos. 122 133 137 139 140 158 160 161 164 166 180 197 199 200 205 207 209 220 223

47703722 09/09/2015

55.8 [55.050] / 5

Designation Lever Window seal Door lock Plug Hinge Countersunk screw Hexagon head screw Socket head cap screw Countersunk screw Hexagon head screw Plate screw Washer Spring washer Washer Washer Washer Washer Nut Nut

Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system

Blower - Remove 1. Refer to Heating - Remove (50.100) and remove the cab heater unit.

SS12M157

1

SS12M163

2

2. Disconnect the connectors.

3. Remove the blower unit.

47703722 09/09/2015

55.8 [55.050] / 6

Electrical systems - Heating, Ventilation, and Air-Conditioning (HVAC) control system

Blower - Install 1. Install the blower unit.

2. Connect the connectors.

SS12M163

1

SS12M157

2

3. Refer to Cab heater - Install (50.100) and install the cab heater unit.

4. Check for leaks and serviceability.

47703722 09/09/2015

55.8 [55.050] / 7

Index Electrical systems - 55 Heating, Ventilation, and Air-Conditioning (HVAC) control system - 050 Blower - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Blower - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Blower - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

47703722 09/09/2015

55.8 [55.050] / 8

Electrical systems - 55 Wiper and washer system - 518

DV213

47703722 09/09/2015

55.9 [55.518] / 1

Contents Electrical systems - 55 Wiper and washer system - 518

FUNCTIONAL DATA Wiper and washer system Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Rear window wiper motor Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Windshield wiper motor Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

47703722 09/09/2015

55.9 [55.518] / 2

Electrical systems - Wiper and washer system

Wiper and washer system - Component identification

SS13J007

1

47703722 09/09/2015

55.9 [55.518] / 3

Electrical systems - Wiper and washer system

Pos. 1 12 22 26 38 41 42 48 72 74 91 98 101 102 105 110 112 114 116

Designation Cabin Front cover Bolt Bracket Cover Cover Nut Washer Pull rod Plate Bolt Crank Handle Cover Ventilation nozzle Seal Strut Band Rubber profile

Pos. 122 133 137 139 140 158 160 161 164 166 180 197 199 200 205 207 209 220 223

47703722 09/09/2015

55.9 [55.518] / 4

Designation Lever Window seal Door lock Plug Hinge Countersunk screw Hexagon head screw Socket head cap screw Countersunk screw Hexagon head screw Plate screw Washer Spring washer Washer Washer Washer Washer Nut Nut

Electrical systems - Wiper and washer system

SS13G121

2

47703722 09/09/2015

55.9 [55.518] / 5

Electrical systems - Wiper and washer system

Pos. 4 6 7 22 44 48 94 104 105 114 124 125 146 147 160

Designation Padding Cover Cover Bolt Plate Washer Hook Ventilation nozzle Ventilation nozzle Band Roller blind Roller blind Seal Seal Hexagon head screw

Pos. 162 163 165 166 170 179 180 192 193 194 197 198 199 200 223

47703722 09/09/2015

55.9 [55.518] / 6

Designation Hexagon head screw Hexagon head screw Oval head countersunk screw Hexagon head screw Hexagon head screw Screw Plate screw Lock washer Washer Spring washer Washer Washer Spring washer Washer Nut

Electrical systems - Wiper and washer system

SS13G122

3

47703722 09/09/2015

55.9 [55.518] / 7

Electrical systems - Wiper and washer system

Pos. 1 4 6 7 12 17 22 26 37 38 40 41 42 44 46 48 71 72 74 91 94 96 97 98 101 102 103 104 105 110 112 114 116 122 123 124 125

Designation Cabin Padding Cover Cover Front cover Ventilator Bolt Bracket Cover Cover Cover Cover Nut Plate Washer Washer Pull rod Pull rod Plate Bolt Hook Spanner Crank Crank Handle Cover Net Ventilation nozzle Ventilation nozzle Seal Strut Band Rubber profile Lever Lever Roller blind Roller blind

Pos. 130 133 136 137 139 140 141 146 147 155 158 160 161 162 163 164 165 166 170 179 180 192 193 194 197 198 199 200 201 202 205 207 208 209 220 223 247

47703722 09/09/2015

55.9 [55.518] / 8

Designation Stripper Window seal Door lock Door lock Plug Hinge Cover Seal Seal Socket head cap screw Countersunk screw Hexagon head screw Socket head cap screw Hexagon head screw Hexagon head screw Countersunk screw Oval head countersunk screw Hexagon head screw Hexagon head screw Screw Plate screw Lock washer Washer Spring washer Washer Washer Spring washer Washer Spring washer Spring washer Washer Washer Toothed washer Washer Nut Nut Hexagon head screw

Electrical systems - Wiper and washer system

SS13G123

4

47703722 09/09/2015

55.9 [55.518] / 9

Electrical systems - Wiper and washer system

Pos. 9 10 13 16 45 46 47 50 51 53 54 55 58 60 62 63 65 67 69 93 99 100 106 107 111 117

Designation Limit stop Lever Holder Holder Washer Washer Washer Washer Washer Washer Treshold Spring Pane of glass Pane of glass Pane of glass Pane of glass Pane of glass Pane of glass Screw Film Rubber profile Handle Armrest Windscreen washer Strut Feedthrough

Pos. 119 131 134 143 144 145 156 159 161 163 171 172 176 191 195 196 197 199 200 201 202 204 220 221 223 224

47703722 09/09/2015

55.9 [55.518] / 10

Designation Rubber mount Stripper Profile Screw head cover Cover Cover Countersunk screw Hexagon head screw Socker head cap screw Hexagon head screw Countersunk screw Oval head countersunk screw Hexagon head screw Washer Washer Washer Washer Spring washer Washer Spring washer Spring washer Outer washer Nut Nut Nut Hexagon nut

Electrical systems - Wiper and washer system

SS13J008

5

47703722 09/09/2015

55.9 [55.518] / 11

Electrical systems - Wiper and washer system

Pos. 1 8 9 10 11 13 14 15 16 39 45 46 47 50 51 52 53 54 55 57 58 59 60 61 62 63 64 65 66 67 68 69 92 93 99 100

Designation Cabin Limit stop Limit stop Lever Lever Holder Holder Holder Holder Cover Washer Washer Washer Washer Washer Washer Washer Treshold Spring Pane of glass Pane of glass Pane of glass Pane of glass Pane of glass Pane of glass Pane of glass Pane of glass Pane of glass Pane of glass Pane of glass Rear windscreen Screw Plug Film Rubber profile Handle

Pos. 106 107 111 117 119 131 134 138 143 144 145 156 159 160 161 163 171 172 175 176 178 191 195 196 197 199 200 201 202 203 204 220 221 223 224

47703722 09/09/2015

55.9 [55.518] / 12

Designation Armrest Windscreen washer Strut Feedthrough Rubber mount Stripper Profile Plug Screw head cover Cover Cover Countersunk screw Hexagon head screw Hexagon head screw Socker head cap screw Hexagon head screw Countersunk screw Oval head countersunk screw Hexagon head screw Hexagon head screw Eyebolt Washer Washer Washer Washer Spring washer Washer Spring washer Spring washer Washer Outer washer Nut Nut Nut Hexagon nut

Electrical systems - Wiper and washer system

Rear window wiper motor - Remove NOTE: There is a rear wiper motor located on the rear left-hand side and rear right-hand side. The removal procedure is the same for both.

1. Remove the cover bolts.

SS12M159

1

SS12M160

2

SS12M161

3

SS12M165

4

2. Remove the cover.

3. Remove the cover.

4. Remove the wiper arms from outside the cab.

5. Disconnect the wiper connector.

6. Remove the wiper motor.

47703722 09/09/2015

55.9 [55.518] / 13

Electrical systems - Wiper and washer system

Rear window wiper motor - Install NOTE: There is a rear wiper motor located on the rear left-hand side and rear right-hand side. The installation procedure is the same for both.

1. Install the wiper motor from the inside of the cab.

2. Connect the wiper connector.

SS12M165

1

SS12M161

2

SS12M160

3

3. From outside the cab, install the wiper arms.

4. Install the covers.

47703722 09/09/2015

55.9 [55.518] / 14

Electrical systems - Wiper and washer system

5. Install the cover bolts.

SS12M159

47703722 09/09/2015

55.9 [55.518] / 15

4

Electrical systems - Wiper and washer system

Windshield wiper motor - Remove 1. Remove the rear-view mirror.

2. Remove the bolts and cover.

SS13J010

1

SS12M167

2

3. Remove the wiper arms from outside the cab.

4. Disconnect the wiper connector.

5. Remove the wiper motor.

47703722 09/09/2015

55.9 [55.518] / 16

Electrical systems - Wiper and washer system

Windshield wiper motor - Install NOTE: There is a rear wiper motor located on the rear left-hand side and rear right-hand side. The installation procedure is the same for both.

1. Install the wiper motor from the inside of the cab.

2. Connect the wiper connector.

SS12M167

1

SS13J010

2

3. From outside the cab, install the wiper arms.

4. Install the covers with the bolts.

5. Install the rear-view mirror.

47703722 09/09/2015

55.9 [55.518] / 17

Index Electrical systems - 55 Wiper and washer system - 518 Rear window wiper motor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Rear window wiper motor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Windshield wiper motor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Windshield wiper motor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Wiper and washer system - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

47703722 09/09/2015

55.9 [55.518] / 18

Electrical systems - 55 Cab controls - 512

DV213

47703722 09/09/2015

55.10 [55.512] / 1

Contents Electrical systems - 55 Cab controls - 512

FUNCTIONAL DATA Cab controls Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Cab controls Replace the position sensor for neutral and parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Replace the reversing horn sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

47703722 09/09/2015

55.10 [55.512] / 2

Electrical systems - Cab controls

Cab controls - Component identification

SS12K407

1

47703722 09/09/2015

55.10 [55.512] / 3

Electrical systems - Cab controls

Pos. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 20 21 22 23 24 25

Designation Box Right-hand lever Left-hand lever Connecting rod Arm Lever Rocker arm Pull rod Ring Pin Pin Brake assembly Cover Lower cover Cam plate Cam plate Lever Head Ball joint Position sensor Sending unit Pull spring Bolt

Pos. 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 42 43 44 45 50 51 52

47703722 09/09/2015

55.10 [55.512] / 4

Designation Bolt Bolt Bolt Bolt Set screw Bolt Bolt Nut Nut Nut Washer Washer Spring washer Spring washer Spring washer Lock ring Nut Washer Washer Bolt Bush Pin

Electrical systems - Cab controls

Cab controls - Replace the position sensor for neutral and parking brake NOTE: For more details refer to Cab controls - Component identification (55.512).

1. Remove the seat.

2. Replace the position sensor (23) for neutral and parking brake.

3. Adjust gap (X) between the rocker arm (7) and position sensor (23) to 1.5 mm (0.06 in).

4. Install the seat.

SS12M172

47703722 09/09/2015

55.10 [55.512] / 5

1

Electrical systems - Cab controls

Cab controls - Replace the reversing horn sensor NOTE: For more details refer to Cab controls - Component identification (55.512).

NOTICE: Use the below procedure to replace the speed selector on the right-hand control panel. To remove the speed selector, the reversing switch and sprinkling interval control must be removed.

1. Remove the bolts and left-hand panel cover.

SS12M173

1

SS12M060

2

2. Replace the sensor (23) for reversing horn sensor, potentiometer for sprinkling interval control (A), travel controller position sensor (22) and STOP switch (B).

3. Adjust the gap between the arm (5) and sensor (23) to 1.5 mm (0.06 in).

4. Install the left-hand panel cover.

47703722 09/09/2015

55.10 [55.512] / 6

Index Electrical systems - 55 Cab controls - 512 Cab controls - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Cab controls - Replace the position sensor for neutral and parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Cab controls - Replace the reversing horn sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

47703722 09/09/2015

55.10 [55.512] / 7

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

PRINTED IN U.S.A. © 2015 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.

47703722 09/09/2015 EN

SERVICE MANUAL Platform, cab, bodywork, and decals DV213

47703722 09/09/2015

90

Contents Platform, cab, bodywork, and decals - 90

[90.120] Mechanically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 [90.105] Machine shields and guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2

47703722 09/09/2015

90

Platform, cab, bodywork, and decals - 90 Mechanically-adjusted operator seat - 120

DV213

47703722 09/09/2015

90.1 [90.120] / 1

Contents Platform, cab, bodywork, and decals - 90 Mechanically-adjusted operator seat - 120

FUNCTIONAL DATA Operator seat Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Seat suspension unit Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Operator seat Seat suspension unit - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Seat sliding guides Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

47703722 09/09/2015

90.1 [90.120] / 2

Platform, cab, bodywork, and decals - Mechanically-adjusted operator seat

Operator seat - Component identification

SS12K408

1

47703722 09/09/2015

90.1 [90.120] / 3

Platform, cab, bodywork, and decals - Mechanically-adjusted operator seat

Pos. 1 2 3 4 5 6 7 8 9 10 11 12 14

Designation Travel controller Slew Steel plate Steering column Limiter Washer Seat Bolt Rest Rest Switch Case Steering wheel

Pos. 15 16 17 18 20 21 22 23 24 25 26 27 28

47703722 09/09/2015

90.1 [90.120] / 4

Designation Cover Switch Power steering Nut Countersunk screw Bolt Bolt Bolt Washer Spring washer Spring washer Washer Hose

Platform, cab, bodywork, and decals - Mechanically-adjusted operator seat

Seat suspension unit - Component identification

SS12K406

1

47703722 09/09/2015

90.1 [90.120] / 5

Platform, cab, bodywork, and decals - Mechanically-adjusted operator seat

Pos. 1 3 4 5 6 11 12 13 15 18 19 20 21 23 26 27 28 29 30

Designation Frame Bracket Arrester Left pedal Right pedal Cover Cover sheet Fuse Rails Insert Shaft Pin Packing piece Rubber Clamp Thrust ring Bush Cuff Bearing

Pos. 32 33 34 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 53

47703722 09/09/2015

90.1 [90.120] / 6

Designation Washer Pull spring Cylindrical pin Bolt Bolt Bolt Bolt Bolt Countersunk screw Nut Nut Washer Washer Washer Washer Spring washer Spring washer Spring washer Cuff

Platform, cab, bodywork, and decals - Mechanically-adjusted operator seat

Seat suspension unit - Remove 1. Remove the bolts which secures the seat to the rotating frame.

SS12M061

1

SS12M062

2

SS12M063

3

SS12M064

4

2. Remove the rotation stop pedals from both the sides.

3. Remove the seat from the rotating frame.

4. Remove the seat from the cab.

47703722 09/09/2015

90.1 [90.120] / 7

Platform, cab, bodywork, and decals - Mechanically-adjusted operator seat

Operator seat - Install 1. Lift and place the seat in the cab in its correct position in the rotating frame.

SS12M064

1

SS12M063

2

SS12M062

3

SS12M061

4

2. Install the rotation stop pedals on both the sides.

3. Install the seat on the rotating frame with the bolts removed earlier.

47703722 09/09/2015

90.1 [90.120] / 8

Platform, cab, bodywork, and decals - Mechanically-adjusted operator seat

Seat sliding guides - Replace 1. Remove the seat (See Seat suspension unit - Remove (90.120)).

2. Remove the bearing journal nut (44).

SS12M065

1

SS12M066

2

3. Remove the spring (33).

4. Remove the arrester (4).

5. Remove the shaft (19).

6. Remove the bearing. Replace with a new bearing.

7. Reinstall the shaft (19), arrester (4) and spring (33) with the bearing journal nut (44).

8. Install the seat (See Operator seat - Install (90.120)).

47703722 09/09/2015

90.1 [90.120] / 9

Index Platform, cab, bodywork, and decals - 90 Mechanically-adjusted operator seat - 120 Operator seat - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Operator seat - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Seat sliding guides - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Seat suspension unit - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Seat suspension unit - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

47703722 09/09/2015

90.1 [90.120] / 10

Platform, cab, bodywork, and decals - 90 Machine shields and guards - 105

DV213

47703722 09/09/2015

90.2 [90.105] / 1

Contents Platform, cab, bodywork, and decals - 90 Machine shields and guards - 105

FUNCTIONAL DATA Engine hood Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Engine hood Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

47703722 09/09/2015

90.2 [90.105] / 2

Platform, cab, bodywork, and decals - Machine shields and guards

Engine hood - Component identification

SS12N331

1

47703722 09/09/2015

90.2 [90.105] / 3

Platform, cab, bodywork, and decals - Machine shields and guards

Pos. 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

Designation Pull rod Pull rod Hinge Complete hood Orifice plate Orifice plate Orifice plate Pin Packing piece Washer Grille Grille Insulation Insulation Insulation Insulation Insulation Door Grille Pull rod Insulation Insulation Washer Bolt Bolt Bolt Nut Nut Bolt Bolt Countersunk screw Nut Nut

Pos. 34 36 37 38 39 40 41 42 43 44 45 46 47 48 50 51 52 53 54 57 58 61 62 66 67 69 72 73 76 79 81 82

Designation Washer Washer Washer Washer Washer for wood Spring washer Spring washer Bush Suspension Cap Hydraulic cylinder Lock ring Grease nipple Grease nipple Strap Rubber mounting Gasket Rubber buffer Lock Folding step Holder Strip Door Step Step Countersunk screw Bolt Bolt Nut Spring washer Spring washer Washer

47703722 09/09/2015

90.2 [90.105] / 4

Platform, cab, bodywork, and decals - Machine shields and guards

Engine hood - Remove Hood 1. Secure the hood on a lifting device of adequate capacity.

SS12N627

1

SS12N628

2

SS12N629

3

2. Remove the hood mounting bolts on both sides.

3. Remove the hood.

Cylinders Remove the hood.

4. Remove the bolts, spring washers and lock plate which secure the pin.

47703722 09/09/2015

90.2 [90.105] / 5

Platform, cab, bodywork, and decals - Machine shields and guards

Drive out the pin and release the cylinder rod end.

NOTICE: Support the piston rod properly to prevent the damage to the surface.

SS12N630

4

SS12N631

5

SS12N632

6

Remove the safety ring and grease nipple.

Remove the hydraulic cylinder with a crowbar.

5. Remove the hose from the hydraulic cylinder.

47703722 09/09/2015

90.2 [90.105] / 6

Platform, cab, bodywork, and decals - Machine shields and guards

Engine hood - Install Cylinders 1. Install the hose on the cylinder.

2. Install the cylinder head on the frame.

SS12N632

1

SS12N631

2

SS12N630

3

SS12N629

4

3. Secure the cylinder head with the grease fitting and the safety ring.

4. Install the rod end of the cylinder with the pin.

NOTICE: Support the piston rod properly to prevent the damage to the surface.

5. Secure the pin with the bolts, spring washers and lock plate.

47703722 09/09/2015

90.2 [90.105] / 7

Platform, cab, bodywork, and decals - Machine shields and guards

Hood 1. Lift the hood with a lifting device of adequate capacity.

2. Place the hood in its correct installation position.

SS12N627

5

SS12N628

6

3. Attach the hood to the pull rod and the hinge with the hardware removed earlier.

4. Check for leaks and serviceability.

5. Top up the system with oil.

47703722 09/09/2015

90.2 [90.105] / 8

Index Platform, cab, bodywork, and decals - 90 Machine shields and guards - 105 Engine hood - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine hood - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Engine hood - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

47703722 09/09/2015

90.2 [90.105] / 9

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

PRINTED IN U.S.A. © 2015 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.

47703722 09/09/2015 EN

47703722 09/09/2015 EN

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

PRINTED IN U.S.A. © 2015 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.

47703722 09/09/2015 EN