Case DV23 DV26 Vibratory Roller & DV23CC DV26CC Combination Roller Tier 4A (interim) Service Manual

DV23 DV26 Tier 4A (interim) Vibratory Roller DV23CC DV26CC Tier 4A (interim) Combination Roller

SERVICE MANUAL

Printed in U.S.A. Š 2017 CNH Industrial America LLC. All Rights Reserved.

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

Part number 48142067 1st edition English September 2017 Replaces part number 47538930

SERVICE MANUAL DV23CC DV23 DV26CC DV26

48142067 15/09/2017 EN

Contents INTRODUCTION Maintenance .............................................................................. 00 [00.150] Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00.1

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

Brakes and controls .................................................................... 33 [33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1 [33.202] Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2

Hydraulic systems....................................................................... 35 [35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.102] Pump control valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.353] Hydraulic travel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 [35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5 [35.995] Compaction/vibration hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6

Frames and ballasting ................................................................. 39 [39.100] Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1

Steering..................................................................................... 41 [41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1

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

Electrical systems ....................................................................... 55 [55.031] Parking brake electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 48142067 15/09/2017

[55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.019] Hydrostatic drive control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 [55.404] External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8 [55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9

Tools ......................................................................................... 89 [89.165] Water kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89.1

Platform, cab, bodywork, and decals ............................................. 90 [90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 [90.110] Operator platform less cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2

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INTRODUCTION

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Contents INTRODUCTION Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety rules - Ecology and the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety rules - Shop and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety rules - Hydraulic contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Basic instructions - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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

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

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

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

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

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

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

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

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

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

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Safety rules - Ecology and the environment When legislation does not yet rule the treatment of some of the substances required by advanced technology, sound judgment should govern the use and disposal of products of a chemical and petrochemical nature.

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

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

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

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

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

• Avoid spillage when draining off used engine coolant mixtures, engine, gearbox and hydraulic oils, brake fluids, etc.

Do not mix drained brake fluids or fuels with lubricants. Store them safely until they can be disposed of in a proper way to comply with local legislation and available resources.

• Modern coolant mixtures, i.e. antifreeze and other additives, should be replaced every two years. They should not be allowed to get into the soil, but should be collected and disposed of properly.

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

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

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

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

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

Spare parts Only use CNH Original Parts.

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

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

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

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

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

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

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

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

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

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

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

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

Special tools 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

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

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

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

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

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

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

There are two types of contamination: microscopic and visible.

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

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

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

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

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

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

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

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

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

Always wear eye protection when working with batteries.

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

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

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

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

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

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

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

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Basic instructions - 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 information in this manual is up-to-date at the date of the publication. It is the policy of the manufacturer for continuous improvement. Some information could not be updated due to modifications of a technical or commercial type, or changes to the laws and regulations of different countries.

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

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Torque NOTICE: The screws can loosen due to the vibration of the roller!

Unless otherwise specified, secure all screws with LOCTITE® 242®.

The values below apply: • Unless otherwise specified in the manual • To female steel threads

Hexagon screws/bolts and hexagon-socket-head cap screws AF size hexagon 7 8 10 13 13 15 17 19 19 19 22 24 24 30 30

AF size hexagon socket 3 4 5 6 6 8 10 10 12 14 -

Screw diameter M4 M5 M6 M8 M8 M 10 x 1.25 M 10 M 12 M 12 M 14 x 1.5 M 14 M 16 M 16 M 20 M 20

Steel quality 8.8 8.8 8.8 8.8 10.9 10.9 8.8 8.8 10.9 10.9 8.8 8.8 10.9 8.8 10.9

Tightening torque 3 N·m (2.2 lb ft) 6 N·m (4.4 lb ft) 10 N·m (7.4 lb ft) 25 N·m (18.4 lb ft) 36 N·m (26.6 lb ft) 90 N·m (66.4 lb ft) 48 N·m (35.4 lb ft) 84 N·m (62.0 lb ft) 123 N·m (90.7 lb ft) 246 N·m (181.4 lb ft) 133 N·m (98.1 lb ft) 206 N·m (151.9 lb ft) 302 N·m (222.7 lb ft) 415 N·m (306.1 lb ft) 592 N·m (436.6 lb ft)

Extremely low-profile cheese-head screws Allen key size 3 3 4 5

Screw diameter M M M M

5 6 8 10

Steel quality

Tightening torque 3 N·m (2.2 lb ft) 6 N·m (4.4 lb ft) 13 N·m (9.6 lb ft) 25 N·m (18.4 lb ft)

Steel quality

Tightening torque 2.5 N·m (1.8 lb ft) 5 N·m (3.7 lb ft) 8 N·m (5.9 lb ft) 12 N·m (8.9 lb ft)

Steel quality

Tightening torque 3.8 N·m (2.8 lb ft) 6.6 N·m (4.9 lb ft) 16 N·m (11.8 lb ft)

Steel quality

Tightening torque 43 N·m (31.7 lb ft)

10.9 10.9 10.9 10.9

Flanged oval-head screws Allen key size 2.5 3 4 5

Screw diameter M M M M

4 5 6 8

10.9 10.9 10.9 10.9

Countersunk head screws Allen key size 3 4 5

Screw diameter M5 M6 M8

10.9 10.9 10.9

Shoulder screws Allen key size 6

Screw diameter M 10

12.9

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INTRODUCTION

Operator seat, seat belt fastening screws AF size hexagon key 5/8“

Screw diameter UNF 7/16”

Steel quality 8.8

Tightening torque 45 N·m (33.2 lb ft)

Drain cock Drain cock Diesel tank

Secure the screw connections with LOCTITE® 565™ PST and tighten by hand, not with torque.

Secure the screw connections with LOCTITE® 565™ PST and tighten by hand, not with torque.

Hydraulic tank

Threaded bolt for ROPS joint Screw diameter M 18

Steel quality S355

Tightening torque 147 N·m (108.4 lb ft) ( 30 kg (66 lb) on 50 cm (20 in) lever)

Grease with LOCTITE® ANTI-SEIZE lubricating compound, for example.

Threaded adapters / Metric threads Thread size M10x1.0 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M22x1.5 M26x1.5 M33x2.0 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5 M27x1.5

Cutting ring 18 N·m (13.3 lb ft) 25 N·m (18.4 lb ft) 45 N·m (33.2 lb ft) 55 N·m (40.6 lb ft) 70 N·m (51.6 lb ft) 125 N·m (92.2 lb ft) 180 N·m (132.8 lb ft) 310 N·m (228.6 lb ft) 35 N·m (25.8 lb ft) 55 N·m (40.6 lb ft) 70 N·m (51.6 lb ft) 110 N·m (81.1 lb ft) 150 N·m (110.6 lb ft) 170 N·m (125.4 lb ft) 270 N·m (199.1 lb ft)

Soft seat ring 18 N·m (13.3 lb ft) 25 N·m (18.4 lb ft) 45 N·m (33.2 lb ft) 55 N·m (40.6 lb ft) 70 N·m (51.6 lb ft) 125 N·m (92.2 lb ft) 180 N·m (132.8 lb ft) 310 N·m (228.6 lb ft) 40 N·m (29.5 lb ft) 40 N·m (29.5 lb ft) 70 N·m (51.6 lb ft) 90 N·m (66.4 lb ft) 125 N·m (92.2 lb ft) 135 N·m (99.6 lb ft) 180 N·m (132.8 lb ft)

6 8 10 12 15 18 22 28 6 8 10 12 14 16 20

Nominal joint size L L L L L L L L S S S S S S S

Soft seat ring 18 N·m (13.3 lb ft) 25 N·m (18.4 lb ft) 45 N·m (33.2 lb ft) 55 N·m (40.6 lb ft) 70 N·m (51.6 lb ft) 125 N·m (92.2 lb ft) 180 N·m (132.8 lb ft) 310 N·m (228.6 lb ft) 40 N·m (29.5 lb ft) 40 N·m (29.5 lb ft) 70 N·m (51.6 lb ft) 90 N·m (66.4 lb ft) 125 N·m (92.2 lb ft) 135 N·m (99.6 lb ft) 180 N·m (132.8 lb ft)

6 8 10 12 15 18 22 28 6 8 10 12 14 16 20

Nominal joint size L L L L L L L L S S S S S S S

Threaded adapters / Inch threads Thread size 1/8“ 1/4“ 1/4“ 3/8“ 1/2“ 1/2“ 3/8“ 1" 1/4“ 1/4“ 3/8“ 3/8“ 1/2“ 1/2“ 3/4“

Cutting ring 18 N·m (13.3 lb ft) 25 N·m (18.4 lb ft) 45 N·m (33.2 lb ft) 55 N·m (40.6 lb ft) 70 N·m (51.6 lb ft) 125 N·m (92.2 lb ft) 180 N·m (132.8 lb ft) 310 N·m (228.6 lb ft) 35 N·m (25.8 lb ft) 55 N·m (40.6 lb ft) 70 N·m (51.6 lb ft) 110 N·m (81.1 lb ft) 150 N·m (110.6 lb ft) 170 N·m (125.4 lb ft) 270 N·m (199.1 lb ft)

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NOTE: To tighten hydraulic hoses and fittings: Screw the union nut by hand all the way to the stop, then tighten ¼ of a turn with the wrench ( 90° )

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Special tools Assembly tool for pressure plate

SVIL13COM0163AB

1

SVIL13COM0293AC

2

SVIL13COM0167AB

3

SVIL13SPT0599AB

4

Assembly tool, pressure plate for puller

Assembly tool, puller for roller drum

Assembly tool for pendulum joint

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Assembly tool for SpeedySleeve ring ø60x19/16 SpeedySleeve shaft protection ring 10-ml bottle of LOCTITE® 603™

SVIL13COM0173AB

5

SVIL13SPT0591AB

6

SVIL13SPT0610AB

7

SVIL13SPT0611AB

8

Assembly tool for steering cylinder

Assembly tool for vibro bearing

Assembly tool for joint bearing

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Capacities Fuel tank Capacity Specifications

40 L (10.57 US gal) #2 Diesel, ultra-low sulfur

Engine crank case oil Capacity Specifications

7.0 L (7.4 US qt) CASE AKCELA UNITEK NO. 1™ SBL CJ-4 SAE 10W-40

Hydraulic system Capacity Specifications

16.0 L (4.2 US gal) CASE AKCELA NEXPLORE™ FLUID

Coolant Capacity Specifications

3.7 L (1.0 US gal) CNH XHD HEAVY DUTY COOLANT / ANTI-FREEZE

Grease As required CASE AKCELA 251H EP MULTI-PURPOSE GREASE

Quantity Specifications

Water tank Quantity Specifications

200 L (52.83 US gal) Water

Gear lube As required TUTELA HYPOIDE EP GEAR LUBE SAE 80W-90

Quantity Specifications

Emulsion tank Quantity

12.5 L (3.3 US gal)

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Consumables Lubricant table Brand

Hydraulic oil

Standard

AGIP BLASER BP CASTROL ESSO MOBIL Motorex

ISO VG 46 HVLP DIN 51524 T3 Drive and vibration hydraulics Amica 46 Blasol 148 Bartran HV 46 Hyspin AWH 46 Univis HP 46 Mobil DTE15 Corex HV 46

PANOLIN SHELL TOTAL

HLP Universal 46 Tellus T 46 Equivis ZS 46

Application

Synthetic hydraulic oil based on HE esters ISO 15380 HEES

Grease ISO 2137 DIN 51502

Drive and vibration hydraulics Foodgrease SPM00

Motorex 174 MOLY 218 (steering cylinder) HLP Synth 46

NOTICE: Using the wrong oil can cause damage to the hydraulic controls! Hydraulic tubes decompose.

It is forbidden to change used rollers for use with biodegradable hydraulic oils!

If hydraulic hoses on a roller running on synthetic ester HE need replacing, only those declared by the supplier as being compatible with synthetic esters may be used.

NOTICE: The screws can loosen due to the vibration of the roller!

Unless otherwise specified, secure all screws with LOCTITE® 242®.

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SERVICE MANUAL Maintenance DV23CC DV23 DV26CC DV26

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Contents Maintenance - 00

[00.150] Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00.1

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Maintenance - 00 Start-up - 150

DV23CC DV23 DV26CC DV26

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Contents Maintenance - 00 Start-up - 150

DIAGNOSTIC Machine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Maintenance - Start-up

Machine - Troubleshooting Problem No message on display unit

Possible Cause Drive pump, brake valve or drive motors

No message on display unit

Switch work gear S7

Correction • Drive the machine against the brake.

If it works, the problem is either with the drive motors or the brake valve, otherwise the problem is with the drive pump.

• Check if the connector is connected.

Diesel engine Drive pump or servo-block drive pump

• Check if the switching contact is open when the switch is in Transport position.

• Check speed.

• Check pressure.

Machine moves while in the neutral position

• Check the X1 and X2 servo-block injectors.

• Check the neutral position setting.

• Test it by itself.

Drive motor mechanically Drive motors defective No message on display unit

• Check leakage oil volume.

Switch work gear S7

Automatic vibration switch S7

No message on display unit

Vibration frequency too low

Machine vibrates only at the front and/or only at one amplitude or frequency

• Check for abraded metal in leakage oil.

• Check if the connector is connected.

• Check if the switching contact is open when the switch is in work gear position.

• Check if the vibration works when the machine is moving.

Vibration buttons S4 and S16

• The switching contact must be open when the switch is set to Manual mode.

• Check if the connector is connected.

Relay K4 Vibration switching valve Y5, Y6, Y7, Y8

• Check the button.

• Check the relay K4.

• Check the solenoids.

Relay K13 (optional)

• Check the connectors on the magnetic coils.

• Check the relay.

Rear vibration switch S8

• The relay must switch (+ 12 V on connection 87) as soon as vibration is switched on.

• Check if the connector is connected.

• Check if the switching contact is closed when the switch is in double vibration position.

Vibration switching valve Y5, Y6, Y7, Y8

• Check the vibro switch valve.

• Check the connectors on the magnetic coils.

Diesel engine

• Check the solenoids.

• Check the speed.

Vibro pump Vibro switch valve Vibro shaft (only on DV36/45 machines) Vibration selector switch S14

• • • •

Relay K15 and K16

• Check the relays.

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Check the vibro pump.

Check the vibromotor.

Check the eccentrics on the vibro shaft.

Check if the connector is connected.

Maintenance - Start-up

Problem

Possible Cause Correction Vibration switching valve Y5, Y6, Y7, Y8 • Check the connectors on the magnetic (only on DV36/45 machines) coils.

• Check the solenoids.

Automatic vibration does Automatic vibration switch S7 not work or does not work properly

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• Check wiring against wiring diagram.

• Check if the connector is connected.

• The switching contact must be closed when the switch is set to Automatic mode.

Index Maintenance - 00 Start-up - 150 Machine - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3

CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404

SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. Š 2017 CNH Industrial America LLC. All rights reserved.

No part of the text or illustrations of this publication may be reproduced.

CNH Industrial America LLC reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at the time of publication, but are subject to change without notice.

Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your CASE CONSTRUCTION dealer.

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

Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.

48142067 15/09/2017 EN

SERVICE MANUAL Engine DV23CC DV23 DV26CC DV26

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10

Contents Engine - 10

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

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Engine - 10 Engine and crankcase - 001

DV23CC DV23 DV26CC DV26

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Contents Engine - 10 Engine and crankcase - 001

SERVICE Engine Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

DIAGNOSTIC Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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Engine - Engine and crankcase

Engine - Service instruction All internal engine repairs are to be performed by a licensed Yanmar engine dealer. Please contact your local Yanmar engine dealer for details.

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Engine - Engine and crankcase

Engine - Adjust NOTICE: Make sure to adjust the speed while the roller is at its operating temperature.

1. Put the machine on two large or four small old tires or on a suitably soft base.

SVIL13COM0520AB

1

SVIL13COM0507AB

2

SVIL13COM0058AB

3

SVIL13COM0056AB

4

2. Move the speed lever to the highest setting: 100% = Fast speed = Reference value of 2360 – 2400 RPM NOTICE: Do not exceed the maximum engine speed of 2400 RPM!

3. Switch on front and rear vibration.

4. Use a tachometer to measure the frequency.

100% = Desired value: 66 Hz 85% = Desired value: 58 Hz

5. If necessary, adjust the speed on the cable knuckle (1) or on the ballhead (2).

NOTE: Source the tachometer locally.

6. Tighten the nuts.

7. Check the fastening (3) on the ball head.

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Engine - Engine and crankcase

Engine RPM Engine RPM, 100% Engine RPM, 85% Simple vibration speed, front Double vibration, front Double vibration, rear Engine RPM under load (driving and double vibration)

At the beginning 2410 – 2450 RPM 2080 – 2180 RPM 3950 – 4050 RPM 3950 – 4050 RPM 3400 – 3600 RPM 2350 – 2400 RPM

After 60 min 2360 – 2400 RPM 2000 – 2100 RPM 3950 – 4050 RPM 3950 – 4050 RPM 3400 – 3600 RPM 2350 – 2400 RPM

At the beginning 85 – 115 bar (1232 – 1668 psi) 40 – 80 bar (580 – 1160 psi)

After 60 min 85 – 115 bar (1232 – 1668 psi) 27 – 43 bar (392 – 624 psi) 55 – 75 bar (798 – 1088 psi)

Pressures Pressures during MA and MB driving operation Pressures for vibratory operation, front Pressures for vibratory operation, front and rear

80 – 140 bar (1160 – 2030 psi)

NOTE: This results in the lower speed, i.e. medium level. Frequency 58 Hz.

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Engine - Engine and crankcase

Engine - Remove 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. Support the hood with a suitable lifting device.

2. Disconnect the lamps (1).

3. Disconnect the hood strut (2).

4. Remove the bolts (3) on the hood hinge.

5. Repeat steps 2 – 4 on the opposite side.

6. Remove the hood.

RAIL13SSL0079BA

1

RAIL13SSL0061BA

2

RAIL13SSL0051BA

3

7. Disconnect the negative battery cable.

8. Remove the U-bolt (1).

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Engine - Engine and crankcase

9. Disconnect and remove the muffler.

RAIL13SSL0069BA

4

RAIL13SSL0048BA

5

RAIL13SSL0059BA

6

10. Disconnect the battery wire (1) on the alternator.

11. Disconnect the regulator connector (2) on the alternator.

12. Disconnect the starter ignition wire (3).

13. Disconnect the battery cable (4) on the starter.

14. Disconnect the ground cable (5).

15. Disconnect the intake snorkel (1).

16. Disconnect the air box snorkel (2).

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Engine - Engine and crankcase

17. Record the position of the throttle cable. Loosen the jam nut (1), and slide the throttle cable away from the mounting bracket.

RAIL13SSL0058BA

7

RAIL13SSL0057BA

8

RAIL13SSL0071BA

9

18. Remove the air box.

19. Disconnect the glow plug wire (1).

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Engine - Engine and crankcase

20. Disconnect and cap the fuel feed hose (1).

21. Disconnect and cap the drain hose (2) for the oil pan.

RAIL13SSL0074BA

10

RAPH13SSL0191BA

11

RAIL13SSL0068BA

12

22. Disconnect the electrical connector (1) for the injection pump solenoid.

23. Disconnect the wire (2) for the oil pressure sender.

24. Disconnect the throttle cable (3).

25. Disconnect the electrical connector (4) for the fuel pump.

26. Disconnect the wire (1) on the coolant temperature sensor.

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Engine - Engine and crankcase

27. Disconnect and cap the fuel return line (1).

RAIL13SSL0056BA

13

RAIL13SSL0066BA

14

RAIL13SSL0043BA

15

28. Remove the P-clamps (1) that retain the engine harness.

29. Install suitable lifting equipment (1) to the engine and pump assembly.

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Engine - Engine and crankcase

30. Remove the bell housing bolts.

RAIL13SSL0046BA

16

RAPH13SSL0193BA

17

RAPH13SSL0194BA

18

31. Remove the engine mount bolts (1).

32. Repeat step 31 on the other side.

33. Remove the engine.

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Engine - Engine and crankcase

Engine - Install 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. Slowly lower the engine into the engine compartment.

RAPH13SSL0194BA

1

RAPH13SSL0193BA

2

RAIL13SSL0046BA

3

2. Apply LOCTITE® 242® to the engine mount bolts (1).

Install the engine mount bolts (1). Torque the engine mount bolts (1) to 84 N·m (62 lb ft).

3. Repeat step 2 on the other side.

4. Apply LOCTITE® 242® to the bell housing bolts. Install the bell housing bolts. Torque the bell housing bolts to 48 N·m (35 lb ft).

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Engine - Engine and crankcase

5. Remove the lifting equipment (1) on the engine and pump assembly.

RAIL13SSL0043BA

4

RAIL13SSL0066BA

5

RAIL13SSL0056BA

6

6. Route the engine harness through the P-clamps, and install the P-clamps (1) to the engine block.

7. Connect the fuel return line (1) to the fuel filter housing.

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Engine - Engine and crankcase

8. Connect the wire (1) to the coolant temperature sensor.

RAIL13SSL0068BA

7

RAPH13SSL0191BA

8

RAIL13SSL0074BA

9

9. Connect the electrical connector (1) for the injection pump solenoid.

10. Connect the wire (2) for the oil pressure sender.

11. Connect the throttle cable (3).

12. Connect the electrical connector (4) for the fuel pump.

13. Connect the fuel feed hose (1) to the water separator.

14. Connect the drain hose (2) for the oil pan.

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Engine - Engine and crankcase

15. Connect the glow plug wire (1).

RAIL13SSL0071BA

10

RAIL13SSL0057BA

11

RAIL13SSL0058BA

12

16. Install the air box.

17. Slide the throttle cable into the mounting bracket. Verify that your previous marking on the throttle cable is in the correct position. Tighten the jam nut (1).

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Engine - Engine and crankcase

18. Connect the intake snorkel (1).

19. Connect the air box snorkel (2).

RAIL13SSL0059BA

13

RAIL13SSL0048BA

14

RAIL13SSL0069BA

15

20. Connect the battery wire (1) to the alternator.

21. Connect the regulator connector (2) to the alternator.

22. Connect the starter ignition wire (3) to the starter.

23. Connect the battery cable (4) to the starter.

24. Connect the ground cable (5) to the engine block.

25. Install the muffler to the exhaust manifold.

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Engine - Engine and crankcase

26. Install the U-bolt (1).

RAIL13SSL0051BA

16

RAIL13SSL0061BA

17

RAIL13SSL0079BA

18

27. Connect the negative battery cable.

28. Carefully lower the hood into position.

29. Install the bolts (3) on the hood hinge.

30. Connect the hood strut (2).

31. Connect the lamps (1).

32. Repeat steps 29 – 27 on the opposite side.

33. Remove the lifting equipment from the hood.

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Engine - Engine and crankcase

Engine - Troubleshooting Problem Starter does not turn

Possible Cause Battery G2 Ignition switch S1

Emergency stop switch S2

• Check if the connector 50 (pin 7) has + 12 V in start position.

• Check if the emergency stop switch is released.

• Check connections and connector X23.

• Check fuse F22.

• Check if the connector is connected to the alternator.

Fuse F22 Alternator G1

• Check if the connection D+ has 0 V with the ignition on.

• Check if the connector is connected.

• Check if the connector 50 has + 12 V in ignition start position.

• Check if there is enough diesel in the tank.

Starter relay K7 Starter motor M1 Starter turns but engine doesn’t start

Correction • Check the battery voltage.

• Check if the control lamps light up on the Instrument panel when the ignition is switched on.

Diesel pump M3

Fuse F21 Timer K2 Relay K3 (pull-in solenoid) Emergency stop switch S2 Connector X50 Pull-in/holding solenoid Y1

• • • • • • •

Check if the diesel pump works.

Check Fuse F21.

Check if the connector is connected.

Check if the connector is connected.

Check connections and connector X14.

Check if the connector is connected.

Check if the holding solenoid has + 12 V when the ignition is on.

• Check if the pull-in solenoid has + 12 V for 0.5 s in ignition start position.

• Check the pre-heating system, in cold weather condition.

Pre-heating coil R1

• Check if the control lamp H8 light up and the heater plug has + 12 V in ignition pre-heating position.

• Check if there is enough diesel in the tank.

Diesel

• Check if diesel flow line is free.

• Check if air in injection system.

• Check if filter is free.

• Check if there is air in the system.

• Check if there are smoke signals from the exhaust talpipe.

• Check the compression injection system valve play.

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Index Engine - 10 Engine and crankcase - 001 Engine - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Engine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

Engine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Engine - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Engine - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

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Engine - 10 Engine cooling system - 400

DV23CC DV23 DV26CC DV26

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Contents Engine - 10 Engine cooling system - 400

SERVICE Radiator Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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Engine - Engine cooling system

Radiator - Drain fluid 1. Lift the hood.

RAIL15COM0384BA

1

RAIL15COM0383BA

2

2. Place a container under the cooler. Drain the coolant.

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Engine - Engine cooling system

Radiator - Remove 1. Remove the expansion tank.

RAIL15COM0385BA

1

RAIL15COM0386BA

2

2. Remove the screws from the bracket that holds the fuel filter.

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Engine - Engine cooling system

3. Remove the hose from the cooler.

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RAIL15COM0387BA

3

RAIL15COM0388BA

4

RAIL15COM0389BA

5

Engine - Engine cooling system

4. Remove the screws of the grid.

RAIL15COM0390BA

6

RAIL15COM0391BA

7

RAIL15COM0392BA

8

5. Remove the screws that attach the cooler to the machine.

6. Remove the screws from the bracket that secures the cooler holder.

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Engine - Engine cooling system

7. Remove the holder with the cooler from the machine.

Remove the screws.

RAIL15COM0393BA

9

8. Remove the screws of the holder.

RAIL15COM0394BA

10

RAIL15COM0397BA

11

9. Take out the cooler.

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Engine - Engine cooling system

Radiator - Install 1. Mount the screws into new cooler.

RAIL15COM0397BA

1

RAIL15COM0394BA

2

RAIL15COM0393BA

3

2. Mount the cooler on the holder.

3. Mount the screws of the holder..

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Engine - Engine cooling system

4. Place the cooler with the holder in the machine. Mount the screws that hold the cooler to the machine.

RAIL15COM0391BA

4

RAIL15COM0392BA

5

RAIL15COM0390BA

6

5. Mount the holder using the screws.

6. Mount the grid using the screws.

NOTICE: Make sure to center the propeller inside the cooler collector.

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Engine - Engine cooling system

7. Mount the hoses using the clips.

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RAIL15COM0387BA

7

RAIL15COM0388BA

8

RAIL15COM0389BA

9

Engine - Engine cooling system

8. Mount the fuel filter using the screws.

RAIL15COM0386BA

10

RAIL15COM0385BA

11

9. Mount the expansion tank using the clip.

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Engine - Engine cooling system

Radiator - Filling 1. Unscrew the tank lid of the radiator 2. Fill the coolant to the specified limit.

3. Check the tightness of the cooling system.

4. Close the engine hood.

RAIL15COM0143AA

NOTICE: DO NOT use any additives in the engine coolant to repair cooling system leakages.

NOTICE: DO NOT refill a hot engine with cold coolant. It could cause damage to the engine castings.

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1

Index Engine - 10 Engine cooling system - 400 Radiator - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Radiator - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

Radiator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

Radiator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404

SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. Š 2017 CNH Industrial America LLC. All rights reserved.

No part of the text or illustrations of this publication may be reproduced.

CNH Industrial America LLC reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at the time of publication, but are subject to change without notice.

Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your CASE CONSTRUCTION dealer.

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

Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.

48142067 15/09/2017 EN

SERVICE MANUAL Hydrostatic drive DV23CC DV23 DV26CC DV26

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Contents Hydrostatic drive - 29

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

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Hydrostatic drive - 29 Pump and motor components - 218

DV23CC DV23 DV26CC DV26

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Contents Hydrostatic drive - 29 Pump and motor components - 218

TECHNICAL DATA Pump General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Pump and motor components Hydraulic systems - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Motor Travel motor - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Pump Hydrostatic circuit supply pump - Check the supply pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Check the drive pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Hydrostatic circuit supply pump Check the supply pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Motor Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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Hydrostatic drive - Pump and motor components

Pump - General specification

RAIL13COM0021FA

1

Drive pump Callout (1) (2) (3)

Location M1, supply pressure MB, backward drive pressure MB, forward drive pressure

Pressure 23 – 27 bar (334 – 392 psi) 380 – 410 bar (5510 – 5945 psi) 380 – 410 bar (5510 – 5945 psi)

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Hydraulic systems - Component identification

SVIL13COM0630FC

Pos. 1 2 3 4 5 6

Designation Drive pump Vibro pump Drive motor Vibromotor Steering selection valve Vibro switch valve

1

Pos. 7 8 9 10 11

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Designation Steering orbitrol Steering cylinder Hydraulic oil filter Cooler Flow divider (option)

Hydrostatic drive - Pump and motor components

Travel motor - Component identification DV23

SS13A786

1

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Hydrostatic drive - Pump and motor components

Pos. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Designation Socket head cap screw Lock washer Clamp Hose guide Strain washer Hexagon nut Spacer plate Wheel Spacer plate Rubber cushion Wheel disk Washer Hexagon head screw Wheel support Hexagon head screw Lock washer Washer Hexagon nut Hexagon nut Strain washer Set of spare parts

Pos. 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41

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Designation Wheel support Male stud coupling body Male stud coupling body Male stud coupling body Set of spare parts Sealing kit Sealing ring Fluid motor Set of spare parts Male stud coupling body Socket head cap screw O-ring Angle flange connection Jointing compound Circlip Shaft seal ring Sealing kit Gear motor Angle flange connection O-ring

Hydrostatic drive - Pump and motor components

DV26

SS13A785

2

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Pos. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

Designation Socket head cap screw Lock washer Clamp Hose guide Strain washer Hexagon nut Spacer plate Wheel Spacer plate Rubber cushion Wheel disk Washer Hexagon head screw Wheel support Hexagon head screw Lock washer Washer Hexagon nut Hexagon nut Strain washer Set of spare parts

Pos. 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41

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Designation Wheel support Male stud coupling body Male stud coupling body Male stud coupling body Set of spare parts Sealing kit Sealing ring Fluid motor Set of spare parts Male stud coupling body Socket head cap screw O-ring Angle flange connection Jointing compound Circlip Shaft seal ring Sealing kit Gear motor Angle flange connection O-ring

Hydrostatic drive - Pump and motor components

Hydrostatic circuit supply pump - Check the supply pressure 1. Disconnect the brake line (1).

2. Seal the line in such a way that pressure will not force it back open.

SVIL13COM0487AB

1

Method with brake valve NOTE: In order to prevent the seat contact switch from being activated, a second person must sit on the operator seat while the pressure is being checked.

1. Connect the 40 bar (580 psi) pressure gauge.

2. Start the engine and set it to maximum speed.

3. Reading: 23 – 27 bar (334 – 392 psi)

SVIL13COM0508AB

2

SVIL13COM0488AC

3

Method without brake valve NOTE: This method is recommended if the supply pressure is not reached with the method above.

1. Disconnect the elbow fitting (15L) directly from the brake valve.

NOTICE: Oil can escape and pollute the environment!

Do not disconnect lines 005 and 006! They must remain connected without fail!

2. Seal the elbow fitting (15L) in such a way that pressure will not force it back open.

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Hydrostatic drive - Pump and motor components

Pump - Check the drive pressure 1. Disconnect the 4 high-pressure lines (1).

SVIL13COM0329AB

1

SVIL13COM0327AD

2

SVIL13COM0327AC

3

2. Seal the lines (1) in such a way that pressure will not force them back open.

3. Connect the 400 bar (5800 psi) measuring device to the measuring points (A) and (B).

4. Start the engine and set it to maximum speed.

5. Move the operating lever all the way forward.

Reading: 380 – 410 bar (5510 – 5945 psi) 6. Move the operating lever all the way back.

Reading: 380 – 410 bar (5510 – 5945 psi) NOTICE: Oil can overheat and seals can be damaged.

Only briefly move the operating lever out all the way, max.

5 s.

7. Reconnect all hydraulic hoses after the drive pump test.

8. Start a test run.

9. Check whether the connections are leak-tight.

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Hydrostatic drive - Pump and motor components

Hydrostatic circuit supply pump - Check the supply pressure 1. Disconnect the brake line (1).

2. Seal the line in such a way that pressure will not force it back open.

SVIL13COM0487AB

1

Method with brake valve NOTE: In order to prevent the seat contact switch from being activated, a second person must sit on the operator seat while the pressure is being checked.

1. Connect the 40 bar (580 psi) pressure gauge.

2. Start the engine and set it to maximum speed.

3. Reading: 23 – 27 bar (334 – 392 psi)

SVIL13COM0508AB

2

SVIL13COM0488AC

3

Method without brake valve NOTE: This method is recommended if the supply pressure is not reached with the method above.

1. Disconnect the elbow fitting (15L) directly from the brake valve.

NOTICE: Oil can escape and pollute the environment!

Do not disconnect lines 005 and 006! They must remain connected without fail!

2. Seal the elbow fitting (15L) in such a way that pressure will not force it back open.

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Hydrostatic drive - Pump and motor components

Motor - Remove Removing the wheel support 1. Remove the hose bracket.

SVIL13COM0386AB

1

SVIL13COM0385AB

2

2. Remove the hydraulic hoses from the drive motor.

3. Plug the fittings.

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4. Relieve the pressure on the rubber elements.

A. Use a crane to lift the roller from both sides, one after the other.

B. On both sides, place a spacer plate ( 25 mm (1 in) thick) between the roller drum and the chassis.

5. Lower the chassis.

SVIL13COM0407BB

3

SVIL13COM0396AB

4

SVIL13COM0387AB

5

6. Loosen (do not unscrew) the lower wheel support bolts (1) on the machine’s drive motor side.

7. Remove the upper wheel support bolts (2) on the machine’s drive motor side.

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Hydrostatic drive - Pump and motor components

8. Use a screwdriver to remove the cap on the drive motor’s brake housing.

9.

SVIL13COM0548AB

6

SVIL13COM0549AB

7

SVIL13COM0406AB

8

SVIL13COM0388AB

9

WARNING Roll-over hazard!

Before releasing the brakes, secure the roller against unintentional movement.

Failure to comply could result in death or serious injury.

W1276A

Mount the brake-releasing plate.

10. Remove the spacer plate.

11. Remove the lower bolts on the wheel supports (drive motor side).

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12.

WARNING Heavy parts! The wheel support will fall down unless supported by the nuts.

Attach the wheel support to the crane before removing the last nut.

Failure to comply could result in death or serious injury.

W1271A

For instructions on how to release the brakes, please refer to Parking brake or parking lock - Service instruction Release the Brakes (33.110).

13. Remove the hexagon nuts (1).

SVIL13COM0404AC

10

SVIL13COM0395AB

11

SVIL13COM0105AB

12

SVIL13COM0102AB

13

14. Use the crane to lift the wheel supports away from the roller drum.

Removing the drive motor 15. Remove the hexagon nuts on the wheel disk.

16. Remove the wheel disk.

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17. Remove the hexagon bolts.

18. Lift the drive motor out of support.

SVIL13COM0100AC

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14

Hydrostatic drive - Pump and motor components

Motor - Install Pre-assemble drive motor 1. Apply LOCTITE® 242® to the male nipples (1), (2), and (3).

2. Install the male nipples: One 10L/R1/4 male nipple (1); torque to 29 N·m (21.4 lb ft) Two 16S/R1/2 male nipples (2); torque to 135 N·m (99.6 lb ft) One 10L/R3/8 male nipple (3); torque to 55 N·m (40.6 lb ft)

SVIL13COM0097AB

1

SVIL13COM0098AB

2

SVIL13COM0099AB

3

SVIL13COM0100AE

4

3. Cover the male nipples.

4. Put the spring washers on the bolts.

5. Apply LOCTITE® 242® to the bolts.

6. Mount the hydraulic motor on the wheel support (1) with the bolts, the hexagon nuts (2) and the spring washers (3).

7. Torque the bolts to 85 N·m (62.7 lb ft).

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8. Place the spacer on the motor.

SVIL13COM0101AB

5

SVIL13COM0102AB

6

SVIL13COM0103AB

7

SVIL13COM0104AB

8

9. Place the wheel disk on top.

10. Apply LOCTITE® 242® to the wheel bolts.

11. Screw on the wheel nuts.

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12. Torque the hexagon nuts to 195 N·m (144 lb ft).

SVIL13COM0106AB

9

13. Fasten the brake on the drive motor.

SVIL13COM0107AB

10

SVIL13COM0108AB

11

SVIL13COM0109AB

12

14. Fasten the wheel support on the wheel with the motor and the brake.

15. Apply LOCTITE® 242® to the thread.

16. Install the hexagon nuts (1) and the spring washers (2).

17. Torque to 210 N·m (155 lb ft).

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18. Use the crane to put the wheel support in mounting position.

SVIL13COM0395AB

13

SVIL13COM0404AC

14

SVIL13COM0388AB

15

SVIL13COM0406AB

16

19. Apply LOCTITE® 242® to the hexagon nuts (1).

20. Torque the hexagon nuts (1) to 210.0 N·m (154.9 lb ft).

21. Apply LOCTITE® 242® to the lower bolts on the wheel supports (drive motor side) and install them.

22. Install the weights.

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23. Remove the brake-releasing plate.

SVIL13COM0549AB

17

SVIL13COM0548AC

18

SVIL13COM0387AB

19

24. Install the cap on the drive motor’s brake housing.

25. Apply LOCTITE® 242® to the upper wheel support bolts (2) on the machine’s drive motor side.

26. Torque the upper wheel support bolts (2) to 306 N·m (226 lb ft).

27. Torque the lower wheel support bolts to 306 N·m (226 lb ft).

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28. Relieve the pressure on the rubber elements. • Use a crane to lift the roller from both sides, one after the other.

29. Remove the spacer plate.

30. Lower the chassis.

SVIL13COM0407BB

20

SVIL13COM0396AB

21

SVIL13COM0385AB

22

31. Unplug the fittings.

32. Install the hydraulic hoses from the drive motor.

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33. Apply LOCTITE® 242® to the bolts.

34. Install the hose bracket.

35. Torque the bolts to 10.0 N·m (7.4 lb ft).

SVIL13COM0386AB

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23

Index Hydrostatic drive - 29 Pump and motor components - 218 Hydraulic systems - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Hydrostatic circuit supply pump - Check the supply pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Hydrostatic circuit supply pump - Check the supply pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Motor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

Motor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

Pump - Check the drive pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

Pump - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Travel motor - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404

SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. Š 2017 CNH Industrial America LLC. All rights reserved.

No part of the text or illustrations of this publication may be reproduced.

CNH Industrial America LLC reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at the time of publication, but are subject to change without notice.

Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your CASE CONSTRUCTION dealer.

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

Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.

48142067 15/09/2017 EN

SERVICE MANUAL Brakes and controls DV23CC DV23 DV26CC DV26

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Contents Brakes and controls - 33

[33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1 [33.202] Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2

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Brakes and controls - 33 Parking brake or parking lock - 110

DV23CC DV23 DV26CC DV26

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Contents Brakes and controls - 33 Parking brake or parking lock - 110

SERVICE Parking brake or parking lock Service instruction Release the Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Brakes and controls - Parking brake or parking lock

Parking brake or parking lock - Service instruction Release the Brakes 1. Secure the roller with chocks against rolling away.

SVIL13COM0398AB

1

SVIL13COM0399AB

2

SS13A897

3

2. Secure the roller with the articulated joint lock.

3. Use a wrench to undo the brake pads.

The brake release chocks are in the front chassis, to the left under the light.

4. Remove the bolts.

5. Remove the brake release chocks (2).

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Brakes and controls - Parking brake or parking lock

6. Remove the protective caps on the front and rear drive motor.

SVIL13COM0548AB

4

SVIL13COM0549AB

5

SS13A873

6

7. Screw the brake release chock onto the front left drive motor.

NOTE: Turn the screw in by hand.

8. Turn the wrench approximate one half-turn downward.

NOTE: Wrench rotation on the motor is approximate 180°.

9. Follow the same procedure for the rear right drive motor.

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Index Brakes and controls - 33 Parking brake or parking lock - 110 Parking brake or parking lock - Service instruction Release the Brakes . . . . . . . . . . . . . . . . . . . . . . . .

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3

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Brakes and controls - 33 Hydraulic service brakes - 202

DV23CC DV23 DV26CC DV26

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Contents Brakes and controls - 33 Hydraulic service brakes - 202

SERVICE Brake pump Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Brakes and controls - Hydraulic service brakes

Brake pump - Check If the roller moves in spite of the actuated parking brake switch, you must perform the brake test.

1. Remove the brake hose from the front roller drum drive motor.

SS13A668

1

SS13A669

2

2. Seal the open hose end so that it can be pressurized.

3. Start the roller.

4. Press the parking brake switch.

The brake light must extinguish quickly.

5. Test the forwards and the backwards drive Because the front brake remains activated, the roller does not move.

6. Switch the roller off.

7. Reinstall the brake hose.

8. Repeat the steps 1 to 7 for the rear drive motor.

9. Make absolutely sure that you have reconnected all the brake lines!

10. Start the roller.

The brake light must extinguish quickly.

11. Test the forwards and the backwards drive.

NOTICE: Damage to property through incorrect handling!

If the roller does not behave exactly as described, you have a problem with one or more brakes. The roller is no longer safe for operation.

Have the roller repaired professionally.

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Index Brakes and controls - 33 Hydraulic service brakes - 202 Brake pump - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404

SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. Š 2017 CNH Industrial America LLC. All rights reserved.

No part of the text or illustrations of this publication may be reproduced.

CNH Industrial America LLC reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at the time of publication, but are subject to change without notice.

Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your CASE CONSTRUCTION dealer.

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

Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.

48142067 15/09/2017 EN

SERVICE MANUAL Hydraulic systems DV23CC DV23 DV26CC DV26

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Contents Hydraulic systems - 35

[35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.102] Pump control valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.353] Hydraulic travel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 [35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5 [35.995] Compaction/vibration hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6

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Hydraulic systems - 35 Fixed displacement pump - 104

DV23CC DV23 DV26CC DV26

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Contents Hydraulic systems - 35 Fixed displacement pump - 104

TECHNICAL DATA Pump General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Hydraulic systems - Fixed displacement pump

Pump - General specification

RAIL13COM0021FA

1

Tandem pump Callout (1) (2)

Location M2, vibro pressure M3, steering pressure

Pressure 215 – 235 bar (3118 – 3408 psi) (double vibration) 165 – 185 bar (2392 – 2682 psi)

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Index Hydraulic systems - 35 Fixed displacement pump - 104 Pump - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3

Hydraulic systems - 35 Hydraulic systems - 000

DV23CC DV23 DV26CC DV26

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Contents Hydraulic systems - 35 Hydraulic systems - 000

FUNCTIONAL DATA Hydraulic systems Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic schema (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Hydraulic schema (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE Hydraulic systems Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Replace Vibro switch valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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Hydraulic systems - Component identification

SVIL13COM0630FC

Pos. 1 2 3 4 5 6

Designation Drive pump Vibro pump Drive motor Vibromotor Steering selection valve Vibro switch valve

1

Pos. 7 8 9 10 11

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Designation Steering orbitrol Steering cylinder Hydraulic oil filter Cooler Flow divider (option)

Hydraulic systems - Hydraulic systems

Hydraulic systems - Overview Hydraulic hoses on the front roller drum • (20) = Drive pump (B) • (21) = Drive pump (A) • (22) = Vibro switch valve (M2) • (23) = Brake valve (A1.2)

SVIL13COM0328AB

1

SVIL13COM0331AB

2

SVIL13COM0332AB

3

SVIL13COM0330AB

4

Hydraulic hoses on the front roller drum • (24) = Vibro switch valve (A) • (25) = Vibro switch valve (B) • (26) = Vibro switch valve (M2)

Hydraulic hoses on the rear roller drum • (30) = Drive pump (B) • (31) = Drive pump (A) • (32) = Oil cooler • (33) = Brake valve (A1.1)

Hydraulic hoses on the rear roller drum • (34) = Vibro switch valve (B) • (35) = Vibro switch valve (C) • (36) = Oil cooler

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Hydraulic systems - Hydraulic schema DV23 DV26

SVIL13COM0650HB

1

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Pos. 1 2 3 4 5 6 7 8

Designation Oil cooler Rear drive motor Front drive motor Brake valve Filler, ventilation filter Drive pump Return-line suction filter Hydraulic oil tank

Pos. 9 10 11 12 13 14 15

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Designation Vibro-steering pump Steering orbitrol Steering cylinder Vibro switch valve Vibromotor, front Vibromotor, rear Flow divider (option)

Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic schema DV23CC DV26CC

RAIL17COM0027HA

1

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Pos. 1 2 3 4 5 6 7 8 9

Designation Drive pump Vibration-steering pump Front drive motor not used Steering orbital Steering cylinder Vibration switch valve Vibration motor, front not used

Pos. 10 11 12 13 14 15 16 17

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Designation Oil cooler Return-line suction filter Hydraulic oil tank Filler, ventilation filter Brake valve Drive motor, rear left Drive motor, rear right Flow divider (option)

Hydraulic systems - Hydraulic systems

Hydraulic systems - Adjust All values apply at a hydraulic oil temperature of approximate 60 °C (140 °F) and max. diesel engine speed.

Bleed pressure relief for a maximum of 5 s.

Use the following pressure gauge: For high pressure = min. 400 bar (5800 psi) For supply pressure = min. 40 bar (580 psi)

SVIL13COM0326FC

Pos. 1 2 3 4 5 6 7 8

1

Designation M1 supply pressure of 23 – 27 bar (334 – 392 psi); can only be adjusted using disks.

MB backward drive pressure of 380 – 410 bar (5510 – 5945 psi); measure with the roller drums blocked.

MB forward drive pressure of 380 – 410 bar (5510 – 5945 psi); measure with the roller drums blocked.

M2 vibro pressure of 215 – 235 bar (3118 – 3408 psi) (double vibration).

M3 steering pressure (this measuring connection is installed). 165 – 185 bar (2392 – 2682 psi); if the steering system is at the stop, it can be adjusted with the steering valve.

Set drive pressure backward.

Setting drive pressure forward.

Valve supply pressure (adjustable with spacer disks)

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Vibro switch valve The vibro switch valve is set at the factory.

SVIL13COM0326AC

2

SS13A549

3

SVIL13COM0648AB

4

Setting steering pressure 1. Move the steering all the way out.

2. Unscrew the cover screw (1) with an Allen key.

3. Adjust the pressure using the Allen screw.

Steering pressure 165 – 185 bar (2392 – 2682 psi).

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Max. vibro switch valve pressure 1. Disconnect the vibro hose (16S) .

2. Disconnect the vibro hose (15L).

3. Seal the fittings on the hydraulic hoses in such a way that pressure will not force them open again.

SVIL13COM0340AB

5

SVIL13COM0351AB

6

4. Connect a pressure gauge (min. 250 bar (3625 psi)) to the vibration pressure measuring point.

5. Start the engine and put it to full speed.

6. Switch on vibration and let it run for a maximum of 5 s.

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Hydraulic systems - Replace Vibro switch valve The Vibro switch valve is set at the factory.

SVIL13COM0417AB

1

SVIL13COM0445AC

2

SVIL13COM0447AB

3

SVIL13COM0448AB

4

Example of pressure regulating valve soiling.

NOTE: If this soiling is present, the vibro shaft will not reach its full speed.

1. Unscrew the plug.

2. Unscrew the plug (port B) with an Allen key.

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3. Unscrew the threaded adapter (port A).

SVIL13COM0449AB

5

SVIL13COM0450AB

6

SVIL13COM0451AB

7

SVIL13COM0452AB

8

View of pressure regulating valves.

4. Remove the inner securing ring.

5. Take the whole valve assembly out from the block with the outer securing ring pliers (ring opening pliers).

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6. Remove the plug on the other side, together with the spring and valve head, from the block.

SVIL13COM0453AB

9

7. Use a drift punch to push the valve seat out of the block.

SVIL13COM0454AB

10

SVIL13COM0456AB

11

8. Remove the valve seat, together with the solenoid, from the block.

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SVIL13COM0473EB

12

9. Clean all parts of the disassembled pressure regulating valve and check them for damage.

Pos. 1 2 3 4 5

Designation

Pos. 6 7 8 9

Cover screw Spring Valve head Valve seat Spring

Designation Plunger O-ring Cylinder Inner securing ring

10. Reassemble in the opposite order.

SVIL13COM0459AB

13

SVIL13COM0460AB

14

11. Torque the threaded joints/plugs to 90 N¡m (66.38 lb ft).

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Magnetic coil 1. Apply a voltage of 12 V to the solenoid valve.

SVIL13COM0468AB

15

SVIL13COM0376AB

16

SVIL13COM0461AB

17

2. The valve must be visibly and audibly actuated.

3. Check the gaskets (1) for damage.

4. Measure the solenoid’s resistance.

The value must be 8 – 9 Ω.

NOTE: When reinstalling the solenoid, make sure to apply a torque of 50 N·m (36.88 lb ft).

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Index Hydraulic systems - 35 Hydraulic systems - 000 Hydraulic systems - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Hydraulic systems - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Hydraulic systems - Hydraulic schema (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Hydraulic systems - Hydraulic schema (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Hydraulic systems - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Hydraulic systems - Replace Vibro switch valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

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Hydraulic systems - 35 Pump control valves - 102

DV23CC DV23 DV26CC DV26

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Contents Hydraulic systems - 35 Pump control valves - 102

SERVICE Flow divider Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

DIAGNOSTIC Flow divider Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Flow divider - Check 1. The solenoid valve (1) can be actuated manually.

2. Remove the solenoid (2).

SVIL13COM0309AB

1

SVIL13COM0308AB

2

SVIL13COM0376AB

3

SVIL13COM0466AB

4

3. Unscrew the solenoid valve.

NOTE: Apply a torque of 40 N·m (29.5 lb ft) when reinstalling.

4. Apply a voltage of 12 V to the solenoid valve.

5. The valve must be visibly and audibly actuated.

6. Check the gaskets (1) for damage.

7. Measure the solenoid’s resistance.

The value should be 6 Ω.

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8. Remove the plunger assembly.

9. Unscrew the cover screws on both sides.

SVIL13COM0310AB

5

SVIL13COM0304AB

6

SVIL13COM0305AB

7

SVIL13COM0306AB

8

10. Spring assembly (1).

11. Check the plunger (2) for damage.

12. Check the housing for soiling.

13. After dismantling the plunger assembly, thoroughly clean all the parts.

14. Oil the plunger before reassembly.

15. Check to make sure that the plunger moves smoothly inside the housing.

16. The plunger must not seize in any position.

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17. After reinserting the plunger assembly, simultaneously put the plugs back on the left-hand side and right-hand side and torque them to 100 N¡m (73.8 lb ft).

SVIL13COM0307AB

9

NOTE: In case of faults, jerky driving, check aperture for soiling. If necessary, short-circuit the flow divider = remove the entire piston package.

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Flow divider - Troubleshooting Problem Possible Cause Flow divider doesn’t work Fuse F12 Switch S19

Correction • Check the fuse F12.

• Check if the connector is connected.

• Warning buzzer B12 buzzes as soon as flow divider is switched on.

• Check if the connector is connected.

Flow divider Y11

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Index Hydraulic systems - 35 Pump control valves - 102 Flow divider - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Flow divider - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

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Hydraulic systems - 35 Hydraulic travel system - 353

DV23CC DV23 DV26CC DV26

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Contents Hydraulic systems - 35 Hydraulic travel system - 353

SERVICE Travel motor Remove Wheel - support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install Wheel - support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Remove - Rear drive motor (DV23CC and DV26CC) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install - Rear drive motor (DV23CC and DV26CC) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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Travel motor - Remove Wheel - support 1. Remove the hose bracket.

SVIL13COM0386AB

1

SVIL13COM0385AB

2

2. Remove the hydraulic hoses from the drive motor.

3. Plug the fittings.

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4. Relieve the pressure on the rubber elements.

A. Use a crane to lift the roller from both sides, one after the other.

B. On both sides, place a spacer plate ( 25 mm (1 in) thick) between the roller drum and the chassis.

5. Lower the chassis.

SVIL13COM0407BB

3

SVIL13COM0396AB

4

SVIL13COM0387AB

5

6. Loosen (do not unscrew) the lower wheel support bolts (1) on the machine’s drive motor side.

7. Remove the upper wheel support bolts (2) on the machine’s drive motor side.

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8. Use a screwdriver to remove the cap on the drive motor’s brake housing.

9.

SVIL13COM0548AB

6

SVIL13COM0549AB

7

SVIL13COM0406AB

8

SVIL13COM0388AB

9

WARNING Roll-over hazard!

Before releasing the brakes, secure the roller against unintentional movement.

Failure to comply could result in death or serious injury.

W1276A

Mount the brake-releasing plate.

NOTE: Do not release the brakes.

10. Remove the spacer plate.

11. Remove the lower bolts on the wheel supports (drive motor side).

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12.

WARNING Heavy parts! The wheel support will fall down unless supported by the nuts.

Attach the wheel support to the crane before removing the last nut.

Failure to comply could result in death or serious injury.

W1271A

For instructions on how to release the brakes, please refer to Parking brake or parking lock - Service instruction Release the Brakes (33.110).

13. Remove the hexagon nuts (1).

SVIL13COM0404AC

10

SVIL13COM0395AB

11

14. Use the crane to lift the wheel supports away from the roller drum.

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Travel motor - Install Wheel - support 1. Use the crane to put the wheel support in mounting position.

SVIL13COM0395AB

1

SVIL13COM0404AC

2

SVIL13COM0388AB

3

SVIL13COM0406AB

4

2. Apply LOCTITE® 242® to the hexagon nuts (1).

3. Torque the hexagon nuts (1) to 210.0 N·m (154.9 lb ft).

4. Apply LOCTITE® 242® to the lower bolts on the wheel supports (drive motor side) and install them.

5. Install the weights.

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6. Remove the brake-releasing plate.

SVIL13COM0549AB

5

SVIL13COM0548AC

6

SVIL13COM0387AB

7

7. Install the cap on the drive motor’s brake housing.

8. Apply LOCTITE® 242® to the upper wheel support bolts (2) on the machine’s drive motor side.

9. Torque the upper wheel support bolts (2) to 306 N·m (226 lb ft).

10. Torque the lower wheel support bolts to 306 N·m (226 lb ft).

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11. Relieve the pressure on the rubber elements. • Use a crane to lift the roller from both sides, one after the other.

12. Remove the spacer plate.

13. Lower the chassis.

SVIL13COM0407BB

8

SVIL13COM0396AB

9

14. Unplug the fittings.

15. Install the hydraulic hoses from the drive motor.

SVIL13COM0385AB

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10

Hydraulic systems - Hydraulic travel system

16. Apply LOCTITE® 242® to the bolts.

17. Install the hose bracket.

18. Torque the bolts to 10.0 N·m (7.4 lb ft).

SVIL13COM0386AB

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Hydraulic systems - Hydraulic travel system

Travel motor - Remove - Rear drive motor (DV23CC and DV26CC) DV23CC DV26CC

NOTE: The following procedure has been performed with the complete rear wheel assembly weldment removed from the machine The procedure is being shown bottom side up for clarity only.

1. Remove the M22 wheel nuts.

RAIL17COM0018AA

1

RAIL17COM0008AA

2

RAIL17COM0017AA

3

2. Remove the outer wheel.

3. Remove the inner wheel.

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4. Disconnect all hose or tube connections from the drive motor being removed. Cap all hose and tube connections.

RAIL17COM0009AA

4

RAIL17COM0010AA

5

RAIL17COM0011AA

6

5. Remove and cap the fittings from the drive motor being removed.

NOTE: Tubes and hoses have been removed from both drive motors for clarity only.

6. Remove the six M10 bolts retaining the drive motor.

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7. Remove the drive motor from the housing.

RAIL17COM0012AA

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7

Hydraulic systems - Hydraulic travel system

Travel motor - Install - Rear drive motor (DV23CC and DV26CC) DV23CC DV26CC

1. Drill and then re-thread the housing for M12 bolt threads.

RAIL17COM0013AA

1

RAIL17COM0014AA

2

RAIL17COM0012AA

3

2. Apply LOCTITEÂŽ 221 thread locker to six new M12 x 25 bolts.

3. Install the drive motor and retain with the six retaining bolts.

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4. Torque the six retaining bolts to 85 N·m (63 lb ft).

RAIL17COM0011AA

4

RAIL17COM0010AA

5

RAIL17COM0009AA

6

5. Apply LOCTITE® 221 thread locker to the hose fittings and install in drive motor.

6. Torque the fittings as follows: (1) to 170 N·m (125 lb ft) (2) to 55 N·m (41 lb ft) (3) to 45 N·m (33 lb ft).

7. Install all hoses and tubes to the drive motor.

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8. Clean the threads on the wheel studs and then apply LOCTITE® 221 thread locker.

RAIL17COM0016AA

7

RAIL17COM0017AA

8

RAIL17COM0008AA

9

9. Install the inner wheel.

10. Install the outer wheel and retain with original spring washers and nuts.

11. Torque the wheel nuts to 195 N·m (144 lb ft).

12. Start the unit and check all hoses and tubes for leaks.

13. Shut the unit off and check hydraulic oil level. Add oil as needed.

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Index Hydraulic systems - 35 Hydraulic travel system - 353 Travel motor - Install - Rear drive motor (DV23CC and DV26CC) (*) . . . . . . . . . . . . . . . . . . . . . . . . . .

14

Travel motor - Install Wheel - support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Travel motor - Remove - Rear drive motor (DV23CC and DV26CC) (*) . . . . . . . . . . . . . . . . . . . . . . . .

11

Travel motor - Remove Wheel - support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

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

DV23CC DV23 DV26CC DV26

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

SERVICE Oil filters Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Oil cooler/Heat exchanger Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Oil filters - Replace 1. Fill hydraulic oil.

SVIL13COM0063AB

1

SS13A772

2

SVIL13COM0064AB

3

SVIL13COM0628AB

4

2. Remove fuse (F21) ( 40 A) from the engine compartment.

3. Connect the manometer to supply pressure.

4. Apply weight to seat.

5. Turn the ignition key clockwise to position (III) .

6. Hold the ignition key in this position for a max. of 30 s.

7. Turn the ignition key back to the starting position (0) .

8. Keep repeating this procedure at short intervals until a pressure of 3 – 5 bar (43.5 – 72.5 psi) has built up.

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Re-insert the 40 amp fuses.

Next operation: Check the hydraulic tank for leaks.

Next operation: Check oil level and top up oil as required.

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Oil cooler/Heat exchanger - Remove 1. Remove the floor panel from the platform.

RAIL15COM0339BA

1

RAIL15COM0340BA

2

RAIL15COM0341BA

3

2. Remove the front cover of the steering column.

3. Remove the cover of the steering column

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4. Remove the accelerator lever.

RAIL15COM0342BA

4

RAIL15COM0343BA

5

RAIL15COM0344BA

6

5. Loosen the nut. Remove the accelerator cable.

6. Mark and remove the hydraulic hoses.

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7. Mount the plugs on the ends of the hydraulic hoses.

RAIL15COM0346BA

7

RAIL15COM0347BA

8

RAIL15COM0348BA

9

8. Mark and unplug the connectors S1-1 and X15.

9. Connect the lifting straps from the crane to the base of the seat railing, and suspend the platform.

NOTICE: Hang the platform horizontally.

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10. Remove the nuts of the front of the platform.

RAIL15COM0349BA

10

RAIL15COM0350BA

11

RAIL15COM0366BA

12

11. Remove the two screws from the back of the platform.

12. Lift the platform from the frame.

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Removal of the water tank 13. Disconnect the three sprinkling hoses. Unplug the M4 connector from the pump. Unplug the Y9 connector from the shut-off valve.

RAIL15COM0352BA

13

RAIL15COM0353BA

14

RAIL15COM0354BA

15

14. Remove the screws.

15. Remove the distance plate.

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16. Remove the two screws of the water tank bracket.

RAIL15COM0355BA

16

RAIL15COM0356BA

17

RAIL15COM0357BA

18

17. Disconnect the sprinkling hose.

18. Unplug the connectors X21, E21, E22, X16.

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19. Mount the lifting lug M8. Hang it on the crane.

RAIL15COM0358BA

19

RAIL15COM0359BA

20

RAIL15COM0360BA

21

20. Remove the water tank from the frame.

Removal of the hydraulic oil cooler 21. Mark and remove the hydraulic hoses.

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22. Dismount the screws. Remove the cooler from the machine.

RAIL15COM0361BA

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Hydraulic systems - Reservoir, cooler, and filters

Oil cooler/Heat exchanger - Install 1. Mount the cooler using the screws.

RAIL15COM0360BA

1

RAIL15COM0361BA

2

RAIL15COM0360BA

3

2. Mount the hydraulic hoses.

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Installation of the water tank 3. Place the water tank into the frame.

RAIL15COM0359BA

4

RAIL15COM0358BA

5

RAIL15COM0357BA

6

4. Remove the lifting lug.

5. Plug the connectors X21, E21, E22, X16.

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6. Plug the sprinkling hoses.

RAIL15COM0356BA

7

RAIL15COM0355BA

8

RAIL15COM0353BA

9

7. Secure the water tank in the back using the four screws.

8. Secure the water tank in the front by the strut using the two screws.

9. Mount the screws.

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10. Connect the Y9 connector to the shut-off valve.

11. Connect the M4 connector to the pump.

12. Connect the three sprinkling hoses.

RAIL15COM0352BA

10

RAIL15COM0366BA

11

RAIL15COM0347BA

12

Install the platform 13. Hang the platform on the crane by the seat and the railing.

14. Connect the connectors S1-1 and X15.

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15. Plug the connectors into the panel in the steering column.

RAIL15COM0346BA

13

RAIL15COM0344BA

14

RAIL15COM0343BA

15

16. Mount the four hydraulic hoses on the steering block.

17. Mount the accelerator cable.

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18. Mount the accelerator lever.

RAIL15COM0342BA

16

RAIL15COM0349BA

17

RAIL15COM0350BA

18

19. Mount the nuts of the front of the platform.

20. Mount the two screws at the back of the platform.

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21. Mount the covers of the steering column.

RAIL15COM0341BA

19

RAIL15COM0340BA

20

RAIL15COM0339BA

21

22. Attach the floor panel on the platform.

NOTE: Refill the hydraulic oil to the specified limit.

NOTICE: Check the tightness of the hydraulic system.

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Adjust the Engine speed and the vibration frequency 23. Perform the adjustment of the engine speed on a machine that is warmed to the operating temperature.

Place the machine on two tires or a suitable soft support.

RAIL15COM0377BA

22

RAIL15COM0378BA

23

RAIL15COM0379BA

24

24. Set the accelerator lever to the highest position: 100% = highest speed = 2360 – 2400 RPM NOTICE: Do not exceed the maximum engine speed of 2400 RPM

25. Turn on the vibration of the front and rear drum. Use a tachometer to measure the frequency: Tachometer Order number: 2-90000030 100% = desired value: 66 Hz 85% = desired value: 58 Hz

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26. If necessary, adjust the speed on the articulated joint.

RAIL15COM0380BA

Engine speed 100% engine speed 85% engine speed Vibration speed front Dual vibration*, front Dual vibration*, rear Engine speed under load (steering and dual vibration) * No dual vibration for version K.

2390 2080 3050 3050 3650 2325

– – – – – –

At start 2430 RPM 2180 RPM 4050 RPM 4050 RPM 3850 RPM 2375 RPM

2360 2000 3050 3050 3650 2325

– – – – – –

After 60 min 2400 RPM 2100 RPM 4050 RPM 4050 RPM 3850 RPM 2375 RPM

RAIL15COM0381BA

Pressure Includes version K MA, MB pressures during operation with vibration

At start 50 – 150 bar (725 – 2175 psi)

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25

After 60 min 50 – 150 bar (725 – 2175 psi)

26

Hydraulic systems - Reservoir, cooler, and filters

RAIL15COM0381BA

Pressure At start Includes version K Pressures for operation with vibration, 24 – 40 bar (348 – 580 psi) front Pressures for operation with vibration, 47 – 63 bar (682 – 914 psi) front and rear * *No front and rear vibration for version K

27

After 60 min 47 – 63 bar (682 – 914 psi) 72 – 63 bar (1044 – 914 psi)

NOTE: This results in a lower speed, i.e. medium level. A frequency of 58 Hz NOTICE: Before putting the machine into operation again, test all functions of the machine according to the operating manual.

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Index Hydraulic systems - 35 Reservoir, cooler, and filters - 300 Oil cooler/Heat exchanger - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

Oil cooler/Heat exchanger - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Oil filters - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

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Hydraulic systems - 35 Compaction/vibration hydraulic system - 995

DV23CC DV23 DV26CC DV26

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

SERVICE Compaction/vibration hydraulic system Assemble the valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Assemble the valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Compaction/vibration motor Remove Wheel - support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install Wheel - support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Compaction/vibration hydraulic system - Assemble the valve 1. Insert the valve seat, together with the solenoid, into the block.

RAIL13COM0023AA

1

SVIL13COM0453AB

2

SVIL13COM0452AB

3

SVIL13COM0451AB

4

2. Install the plug on the other side, together with the spring and valve head, into the block.

3. Insert the whole valve assembly into the block.

4. Install the inner securing ring.

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5. Install the threaded adapter (port A). Torque the threaded adapter to 90 N·m (66 lb ft).

SVIL13COM0449AB

5

SVIL13COM0448AB

6

SVIL13COM0447AB

7

6. Install the plug (port B) with an Allen key. Torque the plug to 90 N·m (66 lb ft).

7. Install the plug. Torque the plug to 90 N·m (66 lb ft).

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Compaction/vibration hydraulic system - Assemble the valve 1. Insert the valve seat, together with the solenoid, into the block.

RAIL13COM0023AA

1

SVIL13COM0453AB

2

SVIL13COM0452AB

3

SVIL13COM0451AB

4

2. Install the plug on the other side, together with the spring and valve head, into the block.

3. Insert the whole valve assembly into the block.

4. Install the inner securing ring.

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5. Install the threaded adapter (port A). Torque the threaded adapter to 90 N·m (66 lb ft).

SVIL13COM0449AB

5

SVIL13COM0448AB

6

SVIL13COM0447AB

7

6. Install the plug (port B) with an Allen key. Torque the plug to 90 N·m (66 lb ft).

7. Install the plug. Torque the plug to 90 N·m (66 lb ft).

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Compaction/vibration motor - Remove Wheel - support 1. Relieve the pressure on the rubber elements.

A. Use a crane to lift the roller from both sides, one after the other.

B. On both sides, place a spacer plate ( 25 mm (1 in) thick) between the roller drum and the chassis.

2. Lower the chassis.

SVIL13COM0408BB

1

SVIL13COM0396AB

2

SVIL13COM0397AB

3

3. Unscrew the clamps on the vibromotor side.

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4. Detach the hydraulic hoses on the vibromotor (1) and plug them.

SVIL13COM0400AB

4

SVIL13COM0401AB

5

SVIL13COM0548AB

6

SVIL13COM0549AB

7

5. Loosen (do not unscrew) the lower wheel support bolts (1) on the vibromotor side.

6. Remove the upper wheel support bolts (2) on the vibromotor side.

7. Use a screwdriver to remove the cap on the drive motor’s brake housing.

8.

WARNING Roll-over hazard!

Before releasing the brakes, secure the roller against unintentional movement.

Failure to comply could result in death or serious injury.

W1276A

Mount the brake-releasing plate.

NOTE: Do not release the brakes.

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9. Lift out the weights.

NOTE: The support can fall down during the next step (unscrewing the lower bolts).

Hold the support or secure it with a crane!

10.

SVIL13COM0406AB

8

SVIL13COM0402AB

9

WARNING Heavy parts! The wheel support will fall down unless supported by the nuts.

Attach the wheel support to the crane before removing the last nut.

Failure to comply could result in death or serious injury.

W1271A

Remove the lower bolts on the wheel supports (vibromotor side).

11. Remove the hexagon nuts (1).

SVIL13COM0133AB

10

SVIL13COM0095AB

11

12. Lift the support (1) away.

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Compaction/vibration motor - Install Wheel - support 1. Install the support (1).

SVIL13COM0095AB

1

SVIL13COM0133AB

2

SVIL13COM0402AB

3

SVIL13COM0406AB

4

2. Apply LOCTITE® 242® to the hexagon nuts (1).

3. Torque the hexagon nuts (1) to 210.0 N·m (154.9 lb ft).

4. Apply LOCTITE® 242® on the lower bolts on the wheel support (vibromotor side) and install them.

5. Mount the weights.

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6. Remove the brake-releasing plate.

SVIL13COM0549AB

5

SVIL13COM0548AC

6

SVIL13COM0401AB

7

SVIL13COM0400AB

8

7. Install the cap on the drive motor’s brake housing.

8. Apply LOCTITE® 242® to the upper wheel support bolts (2) on the vibromotor side.

9. Torque the upper wheel support bolts (2) to 306 N·m (226 lb ft) .

10. Torque the lower wheel support bolts (1) to 306 N·m (226 lb ft).

11. Attach the hydraulic hoses on the vibromotor (1).

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12. Apply LOCTITE® 242® to the bolts.

13. Torque the clamps on the vibromotor side to 10.0 N·m (7.4 lb ft).

SVIL13COM0397AB

9

14. Relieve the pressure on the rubber elements.

• Use a crane to lift the roller from both sides, one after the other.

15. Remove the spacer plate.

16. Lower the chassis.

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SVIL13COM0408BB

10

SVIL13COM0396AB

11

Index Hydraulic systems - 35 Compaction/vibration hydraulic system - 995 Compaction/vibration hydraulic system - Assemble the valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Compaction/vibration hydraulic system - Assemble the valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Compaction/vibration motor - Install Wheel - support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

Compaction/vibration motor - Remove Wheel - support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404

SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. Š 2017 CNH Industrial America LLC. All rights reserved.

No part of the text or illustrations of this publication may be reproduced.

CNH Industrial America LLC reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at the time of publication, but are subject to change without notice.

Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your CASE CONSTRUCTION dealer.

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

Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.

48142067 15/09/2017 EN

SERVICE MANUAL Frames and ballasting DV23CC DV23 DV26CC DV26

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Contents Frames and ballasting - 39

[39.100] Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1

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Frames and ballasting - 39 Frame - 100

DV23CC DV23 DV26CC DV26

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Contents Frames and ballasting - 39 Frame - 100

FUNCTIONAL DATA Articulation frame pivot Component identification - Pendulum joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Component identification - Pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Articulation frame pivot Check - Pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Check - Pendulum joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Replace - Pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Replace - Pendulum joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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Articulation frame pivot - Component identification - Pendulum joint

SS13A781

1

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Pos. 1 2 3 4 5 6

Designation Hexagon head screw Cover Flange Hexagon head screw Threaded rod with drilled hole Pivot bearing

Pos. 7 8 9 10 11 12

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Designation Pendulum limit stop Lock washer Hexagon head screw Strain washer Hexagon head screw Swing joint

Frames and ballasting - Frame

Articulation frame pivot - Component identification - Pendulum support

SS13A792

1

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Pos. 1 2 3 4 5 6

Designation Support Hexagon head screw Strain washer Bearing pin Joint head Support

Pos. 7 8 9 10 11 12

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Designation Hexagon head screw Lock washer Hexagon head screw Supporting pillar Hexagon nut Pendulum support

Frames and ballasting - Frame

Articulation frame pivot - Check - Pendulum support Check the pendulum support once a year for excessive play.

The play can be checked by alternately applying and releasing upward pressure to the roller (visual inspection).

Replace the pendulum support if there is more play than 2 mm (0.08 in).

If the play is more than 2 mm (0.08 in) you will also hear some objectionable grinding noises coming from the pendulum support or the pendulum joint during operation.

If necessary replace the pendulum support. Refer to Articulation frame pivot - Replace - Pendulum support (39.100).

1. Attach the roller to a crane (central lifting point).

2. Lift and lower the roller to check the play.

SVIL13COM0193AB

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1

Frames and ballasting - Frame

Articulation frame pivot - Check - Pendulum joint Check the pendulum joint once a year for excessive play. If the axial play is greater than 5 mm (0.20 in), the joint bearing must be replaced (refer to Articulation frame pivot - Replace (39.100)).

1. Attach the roller to a crane (central lifting point).

2. Lift and lower the roller to check the play.

SVIL13COM0194AB

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Frames and ballasting - Frame

Articulation frame pivot - Replace - Pendulum support Replacing the joint head 1. Fit the joint protection.

SVIL13COM0399AB

1

SVIL13COM0029AB

2

SVIL13COM0044AB

3

SVIL13COM0366AB

4

2. Place the hydraulic jack at the center of the pendulum joint.

3. Slightly relieve the pressure on the roller.

4. Remove the floor panel.

5. Disconnect the three water lines (1).

6. Disconnect the connector (M4) from the water pump.

7. Disconnect the connector (Y9) from the shutoff valve.

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8. Remove the hexagon bolts with washers.

9. Take out the water pump.

SVIL13COM0042AB

5

SVIL13COM0009AB

6

SVIL13COM0010AB

7

SVIL13COM0011AB

8

10. Remove all the cable ties on the hose bundle.

11. Use an Allen key to remove the hose bracket.

12. Temporarily strap the left hose bundle (1) onto the oil cooler in order to create more space.

13. Temporarily strap the right hose bundle (2) onto the driver’s position in order to create more space.

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Frames and ballasting - Frame

14. Remove the rear securing screw with the washer.

SVIL13COM0012AB

9

SVIL13COM0013AB

10

SVIL13COM0014AB

11

SVIL13COM0015AB

12

15. Remove the front securing screw with the washer.

16. Remove the thread protector.

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Frames and ballasting - Frame

17. Mount the puller on the front.

18. Pull out the bolt.

SVIL13COM0016AB

13

SVIL13COM0017AB

14

SVIL13COM0018AB

15

SVIL13COM0019AB

16

19. Mount the impact puller on the back.

20. Pull out the bolt.

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21. Remove the pendulum support.

SVIL13COM0020AB

17

SVIL13COM0021AB

18

SVIL13COM0023AB

19

SVIL13COM0022AB

20

22. Measure the length of the pendulum support you just removed.

23. Clamp the pendulum support in a vise.

24. Heat up the lock nut to an approximate temperature of 200 °C (392 °F).

25. Remove the lock nut.

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26. Heat up the lock nut on the other side to an approximate temperature of 200 °C (392 °F) as well.

27. Use a wrench to remove the swivel joint yoke from the rod.

SVIL13COM0024AB

21

SVIL13COM0027AB

22

SVIL13COM0028AB

23

SVIL13COM0021AB

24

28. Apply LOCTITE® 242® to the inner thread of the new joint head and to the outer thread of the pendulum support.

29. Screw the joint head onto the pendulum support all the way to the stop.

30. Adjust the pendulum support until it has the length you measured previously.

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Frames and ballasting - Frame

31. Apply LOCTITE® 271™ to the lock nut.

SVIL13COM0025AB

25

SVIL13COM0026AB

26

SVIL13COM0030AB

27

SVIL13COM0031AB

28

32. Tighten the lock nut.

33. Grease the inside of the joint head with LOCTITE® ANTI-SEIZE lubricating compound.

34. Grease the bolt with LOCTITE® ANTI-SEIZE lubricating compound.

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35. Install the bolt in the front.

SVIL13COM0035AB

29

SVIL13COM0032AB

30

SVIL13COM0033AB

31

SVIL13COM0034AB

32

36. Grease the bolt with LOCTITE® ANTI-SEIZE lubricating compound.

37. Install the bolt in the back.

38. Apply LOCTITE® 242® to the securing screws with the washers.

39. Install the front and rear screws and torque them to 48 N·m (35.4 lb ft).

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40. Apply LOCTITE® 242® to the bolts.

SVIL13COM0036AB

33

SVIL13COM0037AB

34

SVIL13COM0038AB

35

41. Install the bracket.

42. Put the hose bundles back in place.

43. Secure them with cable ties.

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Frames and ballasting - Frame

44. Use instant adhesive to glue the washers to the bracket.

SVIL13COM0039AB

36

SVIL13COM0040AB

37

SVIL13COM0041AB

38

SVIL13COM0042AB

39

45. Apply LOCTITE® 242® to the hexagon bolts with washers.

46. Install the water pump.

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47. Connect the three water lines (1).

48. Connect the connector (M4) to the water pump.

49. Connect the connector (Y9) to the shutoff valve.

SVIL13COM0366AB

40

SVIL13COM0043AB

41

SVIL13COM0044AB

42

SVIL13COM0029AB

43

50. Apply LOCTITE® 242® to the hexagon bolts.

51. Install the floor panel and torque the bolts to 24 N·m (17.7 lb ft).

52. Remove the hydraulic jack.

53. Release the joint protection.

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Frames and ballasting - Frame

Articulation frame pivot - Replace - Pendulum joint Replacing the bearing 1. Fit the joint protection.

SVIL13COM0399AB

1

SVIL13COM0410AB

2

SVIL13COM0411AB

3

SVIL13COM0412AB

4

2. Use hydraulic jacks to support the chassis in the front and the back.

3. Remove the securing bolt for the steering cylinder bolt.

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Frames and ballasting - Frame

4. Remove the thread cap.

SVIL13COM0413AB

5

SVIL13COM0414AB

6

SVIL13COM0415AB

7

SVIL13COM0416AB

8

5. Pull out the steering cylinder bolt.

6. Start the engine.

7. Turn the steering wheel to the left.

8. Pull the steering cylinder rod out from the bracket so that the bearing is exposed.

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Frames and ballasting - Frame

9. Loosen the hexagon bolts and remove the rod-end bearing cover.

SVIL13COM0418AB

9

SVIL13COM0419AB

10

SVIL13COM0420AB

11

SVIL13COM0421AB

12

10. Remove the hexagon bolt, including the support disk.

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Frames and ballasting - Frame

11. Retap the M16 thread.

SVIL13COM0422AB

13

SVIL13COM0423AB

14

SVIL13COM0424AB

15

SVIL13COM0435AB

16

12. Insert the thrust piece (thread protector).

13. Mount the puller.

14. Remove the hexagon bolts.

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Frames and ballasting - Frame

15. Pull out the entire support pendulum joint with the puller.

SVIL13COM0425AB

17

SVIL13COM0427AB

18

SVIL13COM0426AB

19

SVIL13COM0455AB

20

16. The complete pendulum joint has now been removed.

17. Push out the bearing with the press.

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Frames and ballasting - Frame

18. Lubricate the new bearing.

19. Press the bearing into the support.

SVIL13COM0457AB

21

SVIL13COM0458AB

22

SVIL13COM0428AB

23

SVIL13COM0430AB

24

20. Apply LOCTITE® ANTI-SEIZE lubricating compound to the bearing bolt (1) and the inner bearing ring (2).

21. Put the bearing flange on the bolt.

22. Prepare the assembly hexagon bolt.

A. Add the hexagon nut (1).

B. Add the spring washer (2).

C. Add the protecting disk (3).

D. Grease the thread.

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Frames and ballasting - Frame

23. Move the bearing assembly down with the hexagon bolt.

24. Remove the assembly bolt.

SVIL13COM0431AB

25

SVIL13COM0432AB

26

SVIL13COM0429AB

27

SVIL13COM0433AB

28

25. Apply LOCTITE® 242® to the hexagon bolt.

26. Place the protecting disk on the inner bearing ring.

27. Torque the bolt to 210 N·m (155 lb ft).

28. Prepare the hexagon bolts.

A. Add spring washers.

B. Apply LOCTITE® 242®.

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Frames and ballasting - Frame

29. Install the bearing flange with the hexagon bolts on the front chassis.

Torque to 210 N·m (155 lb ft).

SVIL13COM0434AB

29

SVIL13COM0435AB

30

SVIL13COM0436AB

31

SVIL13COM0437AB

32

30. Apply LOCTITE® 574™ to the bearing flange, the flange, and the cap.

31. Apply LOCTITE® 242® to the hexagon bolts.

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Frames and ballasting - Frame

32. Install the hexagon bolts and torque them to 86 N·m (63.4 lb ft).

SVIL13COM0438AB

33

SVIL13COM0439AB

34

SVIL13COM0440AB

35

33. Start the engine.

34. Use the steering wheel to position the steering cylinder.

35. Lubricate the bolt with LOCTITE® ANTI-SEIZE. 36. Install the bolt.

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Frames and ballasting - Frame

37. Apply LOCTITE® 242® to the hexagon bolt.

38. Install the hexagon bolt with the spring washer (secure the steering cylinder bolt). Torque them to 48 N·m (35.4 lb ft).

SVIL13COM0441AB

36

SVIL13COM0442AB

37

SVIL13COM0443AB

38

SVIL13COM0444AB

39

39. Insert the thread protector (1).

40. Remove the jacks.

41. Release the joint protection.

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Index Frames and ballasting - 39 Frame - 100 Articulation frame pivot - Check - Pendulum joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

Articulation frame pivot - Check - Pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Articulation frame pivot - Component identification - Pendulum joint . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Articulation frame pivot - Component identification - Pendulum support . . . . . . . . . . . . . . . . . . . . . . . .

5

Articulation frame pivot - Replace - Pendulum joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

Articulation frame pivot - Replace - Pendulum support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404

SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. Š 2017 CNH Industrial America LLC. All rights reserved.

No part of the text or illustrations of this publication may be reproduced.

CNH Industrial America LLC reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at the time of publication, but are subject to change without notice.

Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your CASE CONSTRUCTION dealer.

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

Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.

48142067 15/09/2017 EN

SERVICE MANUAL Steering DV23CC DV23 DV26CC DV26

48142067 15/09/2017

41

Contents Steering - 41

[41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1

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Steering - 41 Steering control - 101

DV23CC DV23 DV26CC DV26

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Contents Steering - 41 Steering control - 101

DIAGNOSTIC Steering control Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Steering - Steering control

Steering control - Troubleshooting Problem The steering system is not working

Noises when steering

Possible Cause Steering valve

Correction • Check the steering pressure.

Steering cylinder bearing

• Check if the bearing is greased.

Pendulum support Pendulum joint

• Check if the bearing is worn out.

• Check if the bearing is worn out.

• Check if the bearing is worn out.

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Index Steering - 41 Steering control - 101 Steering control - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404

SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. Š 2017 CNH Industrial America LLC. All rights reserved.

No part of the text or illustrations of this publication may be reproduced.

CNH Industrial America LLC reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at the time of publication, but are subject to change without notice.

Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your CASE CONSTRUCTION dealer.

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

Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.

48142067 15/09/2017 EN

SERVICE MANUAL Wheels DV23CC DV23 DV26CC DV26

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44

Contents Wheels - 44

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

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Wheels - 44 Compaction drums - 160

DV23CC DV23 DV26CC DV26

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Contents Wheels - 44 Compaction drums - 160

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

Compaction rear drum shaft Compaction drums - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE Compaction drums Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Disassemble Drive - bearing - flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Assemble Drive - bearing - flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Disassemble Vibro - bearing - flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Assemble Vibro - bearing - flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Replace the rubber element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Compaction front drum shaft Compaction rear drum shaft - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Compaction rear drum shaft - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Compaction rear drum shaft Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

(*) See content for specific models 48142067 15/09/2017

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Wheels - Compaction drums

Compaction drums - Component identification DV23

SS13A783

1

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Wheels - Compaction drums

Pos. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Designation Hexagon head screw Washer Liquid grease Hub Feather key Circlip Strain washer Hexagon head screw Screw plug Sealing ring Housing Cylindrical roller bearing Shaft seal ring Repair kit

Pos. 15 16 17 18 19 20 21 22 23 24 25 26 27 28

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Designation Mounting aid Repair kit Repair kit Shaft protection sleeve Adhesive Vibrating shaft Flange X-ring Shaft seal ring Clamp ring Grooved ball bearing Bushing Hub Bearing support

Wheels - Compaction drums

DV26

SS13A782

2

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Wheels - Compaction drums

Pos. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Designation Hexagon head screw Washer Liquid grease Hub Feather key Circlip Strain washer Hexagon head screw Screw plug Sealing ring Housing Cylindrical roller bearing Shaft seal ring Repair kit

Pos. 15 16 17 18 19 20 21 22 23 24 25 26 27 28

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Designation Mounting aid Repair kit Repair kit Shaft protection sleeve Adhesive Vibrating shaft Flange X-ring Shaft seal ring Clamp ring Grooved ball bearing Bushing Hub Bearing support

Wheels - Compaction drums

Compaction drums - Component identification DV23

SS13A783

1

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Wheels - Compaction drums

Pos. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Designation Hexagon head screw Washer Liquid grease Hub Feather key Circlip Strain washer Hexagon head screw Screw plug Sealing ring Housing Cylindrical roller bearing Shaft seal ring Repair kit

Pos. 15 16 17 18 19 20 21 22 23 24 25 26 27 28

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Designation Mounting aid Repair kit Repair kit Shaft protection sleeve Adhesive Vibrating shaft Flange X-ring Shaft seal ring Clamp ring Grooved ball bearing Bushing Hub Bearing support

Wheels - Compaction drums

DV26

SS13A782

2

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Wheels - Compaction drums

Pos. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Designation Hexagon head screw Washer Liquid grease Hub Feather key Circlip Strain washer Hexagon head screw Screw plug Sealing ring Housing Cylindrical roller bearing Shaft seal ring Repair kit

Pos. 15 16 17 18 19 20 21 22 23 24 25 26 27 28

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Designation Mounting aid Repair kit Repair kit Shaft protection sleeve Adhesive Vibrating shaft Flange X-ring Shaft seal ring Clamp ring Grooved ball bearing Bushing Hub Bearing support

Wheels - Compaction drums

Compaction drums - Remove NOTE: The procedure for the front drum and the rear drum is the same.

1. Fit the joint protection.

SVIL13COM0399AB

1

SVIL13COM0398AB

2

2. Secure the machine with wheel chocks.

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3. Relieve the pressure on the rubber elements.

A. Use a crane to lift the roller from both sides, one after the other.

B. On both sides, place a spacer plate ( 25 mm (1 in) thick) between the roller drum and the chassis.

4. Lower the chassis.

SVIL13COM0408BB

3

SVIL13COM0396AB

4

SVIL13COM0397AB

5

5. Unscrew the clamps on the left and right wheel supports

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Wheels - Compaction drums

6. Detach the hydraulic hoses on the vibromotor (1) and plug them.

7. Also detach the hydraulic hoses on the drive motor and plug them.

SVIL13COM0400AB

6

SVIL13COM0401AB

7

SVIL13COM0548AB

8

SVIL13COM0549AB

9

8. Loosen (do not unscrew) the lower wheel support bolts (1) on both sides of the machine.

9. Remove the upper wheel support bolts (2) on both sides of the machine.

10. Use a screwdriver to remove the cap on the drive motor’s brake housing.

11.

WARNING Roll-over hazard!

Before releasing the brakes, secure the roller against unintentional movement.

Failure to comply could result in death or serious injury.

W1276A

Mount the brake-releasing plate.

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Wheels - Compaction drums

12. Lift out the spacer plate on both sides of the machine.

NOTE: The support can fall down during the next step (unscrewing the lower bolts).

Hold the support or secure it with a crane!

13.

SVIL13COM0406AB

10

SVIL13COM0402AB

11

SVIL13COM0403AB

12

SVIL13COM0404AB

13

WARNING Heavy parts! The wheel support will fall down unless supported by the nuts.

Attach the wheel support to the crane before removing the last nut.

Failure to comply could result in death or serious injury.

W1271A

Remove the lower bolts on the wheel supports (vibromotor side).

14. Carefully put the support down.

15. Remove the lower bolts on the wheel supports (drive motor side).

16. For instructions on how to release the brakes, please refer to Parking brake or parking lock - Service instruction Release the Brakes (33.110).

17. Carefully put the support down.

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Wheels - Compaction drums

18. Lift the machine.

19. Pull out the roller drum.

SVIL13COM0405AB

14

SVIL13COM0486AB

15

20. Position the roller drum in a suitable workplace.

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Wheels - Compaction drums

Compaction drums - Install NOTE: The procedure for the front drum and the rear drum is the same.

1. Use a crane to lift the machine.

2. Position the roller drum.

3. Secure the machine with wheel chocks.

SVIL13COM0405AB

1

SVIL13COM0396AB

2

SVIL13COM0549AB

3

SVIL13COM0404AB

4

4. Place a spacer plate ( 25 mm (1 in) thick) between the roller drum and the chassis on both sides and lower the machine.

5.

WARNING Roll-over hazard!

Before releasing the brakes, secure the roller against unintentional movement.

Failure to comply could result in death or serious injury.

W1276A

Mount the brake-releasing plate and release the brakes. Refer to Parking brake or parking lock Service instruction Release the Brakes (33.110).

6. Bring the wheel support in the mounting position on the drive motor side.

7. Install the lower bolts on the wheel supports.

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Wheels - Compaction drums

8. Bring the wheel support in the mounting position on the vibromotor side.

SVIL13COM0403AB

5

SVIL13COM0402AB

6

SVIL13COM0406AB

7

SVIL13COM0401AB

8

9. Install the lower bolts on the wheel supports.

10. Install the weight on both sides of the machine.

11. Apply LOCTITE® 242® to the upper wheel support bolts (2) and to the lower wheel support bolts (1).

12. Torque the upper wheel support bolts (2) to 306 N·m (226 lb ft) on both sides of the machine.

13. Torque the lower wheel support bolts (1) to 306 N·m (226 lb ft) on both sides of the machine.

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Wheels - Compaction drums

14. Install the hydraulic hoses on the drive motor.

15. Install the hydraulic hoses on the vibromotor (1).

SVIL13COM0400AB

9

16. Remove the brake-releasing plate.

SVIL13COM0549AB

10

SVIL13COM0548AC

11

17. Install the cap on the drive motor’s brake housing.

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18. Relieve the pressure on the rubber elements. • Use a crane to lift the roller from both sides, one after the other.

19. Remove the spacer plate.

20. Lower the machine.

SVIL13COM0408BB

12

SVIL13COM0396AB

13

SVIL13COM0398AB

14

21. Remove the wheel chocks.

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22. Remove the joint protection.

SVIL13COM0399AB

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15

Wheels - Compaction drums

Compaction drums - Disassemble Drive - bearing - flange Prior operation: Remove the wheel support on the drive motor side. Refer to Travel motor - Remove Wheel - support (35.353) Prior operation: Remove the wheel support on the vibromotor side. Refer to Compaction/vibration motor - Remove Wheel - support (35.995) Prior operation: Remove the drum. Refer to Compaction drums - Remove (44.160).

1. Remove the cheese-head screws from the vibromotor.

SVIL13COM0129AB

1

SVIL13COM0127AB

2

SVIL13COM0060AB

3

2. Remove the hexagon bolts from the drive bearing flange.

3. Pull out the drive bearing flange.

4.

WARNING Heavy object!

Securely fasten the vibro shaft before lifting out.

Failure to comply could result in death or serious injury.

W1275A

Fasten the vibro shaft securely and pull it out.

NOTE: If you do not have the necessary tools, particularly for lifting out the vibro shafts, we recommend placing the roller drum upright. Vibromotor side, top.

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Wheels - Compaction drums

5. Remove the hexagon bolts.

6. Pull out the vibro bearing shaft.

SVIL13COM0132AB

4

SVIL13COM0125AB

5

SVIL13COM0163AB

6

SVIL13COM0164AB

7

7. Remove the hexagon bolts from the butterfly.

8. Mount the pressure plate on the butterfly with the hexagon bolts.

9. Place the complete drive bearing flange on a suitable surface under the press.

10. Insert a compatible press attachment (1) into the housing.

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Wheels - Compaction drums

11. Carefully press the butterfly off the drive bearing flange.

SVIL13COM0165AB

8

SVIL13COM0166AB

9

12. Place the pressure plate on the shaft center.

13. Screw the puller onto the sealing flange.

SVIL13COM0167AB

10

SVIL13COM0168AB

11

14. Pre-tighten the puller with an impact wrench.

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15. Use a gas flame to heat up the bearing to 200.0 °C (392.0 °F) until the bearing comes loose.

SVIL13COM0169AB

12

SVIL13COM0170AB

13

SVIL13COM0171AB

14

SVIL13COM0172AB

15

The drive bearing flange has now been dismantled.

16. Remove the shaft sealing ring inside the drive bearing flange.

17. Remove the inner securing ring.

18. Place the drive bearing flange (1) under the press.

19. Insert the attachment (2).

20. Press out the roller bearing.

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Wheels - Compaction drums

Compaction drums - Assemble Drive - bearing - flange 1. Grease the inside of the flange with 80 g (2.8 oz) of CASE AKCELA GRADE F GEAR LUBE. Total amount of grease for the drive bearing flange = 150 g (5.3 oz)

SVIL13COM0087AB

1

SVIL13COM0116AB

2

SVIL13COM0088AB

3

SVIL13COM0117AB

4

2. Grease the clamp ring with 40 g (1.4 oz) of CASE AKCELA GRADE F GEAR LUBE. Total amount of grease for the drive bearing flange = 150 g (5.3 oz)

3. Place the clamp ring (1) on the flange (2).

4. Apply LOCTITE® 574™ to the clamp ring.

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Wheels - Compaction drums

5. Clean the seat of the bearing with alcohol.

SVIL13COM0118AB

5

SVIL13COM0119AB

6

SVIL13COM0120AB

7

SVIL13COM0121AB

8

6. Apply LOCTITE® 603™ to the seat of the bearing.

7. Attach a temperature sensor to the inner ring.

8. Heat the inner ring to 110 °C (230 °F).

The value is pre-defined by the “Bearing” symbol.

9. Fit the heated bearing onto the flange.

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Wheels - Compaction drums

10. Fit the drive bearing on the seat of the bearing with an installation ring.

11. Grease the bearing with 40 g (1.4 oz) of CASE AKCELA GRADE F GEAR LUBE. Total amount of grease for the drive bearing flange = 150 g (5.3 oz)

SVIL13COM0135AB

9

12. Apply LOCTITE® 242® to the rubber buffers (2).

13. Mount the rubber buffers on the bearing support (butterfly) (1).

SVIL13COM0122AB

10

SVIL13COM0123AB

11

SVIL13COM0124AB

12

14. Place the butterfly on the drive bearing.

15. Put the assembly disk on the assembly.

16. Press the butterfly and the drive bearing flange together.

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Wheels - Compaction drums

17. Put the washers on the hexagon bolts.

18. Apply LOCTITE® 242® to the bolts.

SVIL13COM0090AB

13

SVIL13COM0125AB

14

SVIL13COM0065AB

15

SVIL13COM0126AB

16

19. Torque the bolts to 48 N·m (35.4 lb ft).

20. Put the spring washers on the hexagon bolts.

21. Apply LOCTITE® 242® to the bolts.

22. Torque the bolts to 48 N·m (35.4 lb ft).

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23. Fasten the vibro shaft securely and insert it into the roller drum.

NOTE: The shaft sealing ring can get pushed out while you are inserting the vibro shaft.

Remove the breather screw in the housing!

NOTE: The vibro shaft must be securely fastened in order to insert it.

SVIL13COM0060AB

17

SVIL13COM0065AB

18

SVIL13COM0127AB

19

SVIL13COM0092AB

20

24. Put the spring washers on the bolts.

25. Apply LOCTITE® 242® to the bolts.

26. Fasten the drive bearing flange.

27. Torque the bolts to 48 N·m (35.4 lb ft)

28. Grease the drive bearing flange housing with CASE AKCELA GRADE F GEAR LUBE. Total amount of grease for the drive bearing flange housing = 150 g (5.3 oz)

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29. Measure the vibro shaft’s axial play ( 0.5 – 2.3 mm (0.02 – 0.09 in)).

SVIL13COM0091AB

21

SVIL13COM0128AB

22

SVIL13COM0093AB

23

SVIL13COM0094AB

24

30. Mount the coupling on the shaft.

31. Put LOCTITE® 242® into the threaded hole in the bearing support.

32. Apply LOCTITE® 574™ to the vibromotor.

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33. Assemble the vibromotor onto the bearing support with the cheese-head screws and torque them to 25 N·m (18.4 lb ft).

SVIL13COM0129AB

25

SVIL13COM0130AB

26

SVIL13COM0131AB

27

34. Apply LOCTITE® 242® to the galvanized hexagon socket cover screw (1).

35. Screw in the cover screw (1) and the 13.4 / 10.2x1.0 gasket (2) with a screwdriver.

36. Apply LOCTITE® 242® to the galvanized G1/4” hexagon socket cover screw (1).

37. Screw in the cover screw (1) and the 13.4 / 10.2x1.0 gasket (2) with a screwdriver.

Next operation: Install the drum. Refer to Compaction drums - Install (44.160).

Next operation: Install the wheel support on the drive motor side. Refer to Travel motor - Install Wheel - support (35.353) Next operation: Install the wheel support on the vibromotor side. Refer to Compaction/vibration motor - Install Wheel - support (35.995)

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Compaction drums - Disassemble Vibro - bearing - flange Prior operation: Remove the wheel support on the drive motor side. Refer to Travel motor - Remove Wheel - support (35.353) Prior operation: Remove the wheel support on the vibromotor side. Refer to Compaction/vibration motor - Remove Wheel - support (35.995) Prior operation: Remove the drum. Refer to Compaction drums - Remove (44.160).

1. Screw the lifting device onto the vibro shaft and align it.

SVIL13COM0266AB

1

SVIL13COM0261AB

2

SVIL13COM0162AB

3

2. Lift the vibro shaft away from the roller drum.

3. Unscrew the threaded bolt.

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4. Pull the hub off the vibro shaft with a grip tool.

SVIL13COM0156AB

4

SVIL13COM0157AB

5

SVIL13COM0158AB

6

SVIL13COM0159AB

7

5. Grind out the groove of the inner bearing ring with a suitable tool.

6. Use a chisel to force the inner ring open.

7. Push the inner ring off the shaft.

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8. Use wire cutters to separate the collar from the SpeedySleeve ring.

SVIL13COM0160AB

8

SVIL13COM0161AB

9

9. Carefully grind the SpeedySleeve ring with an appropriate tool until the ring breaks.

A. The ring can easily be pushed off the shaft.

10. Remove the vibro-bearing housing shaft sealing ring with a suitable tool.

SVIL13COM0151AB

10

SVIL13COM0152AB

11

11. The shaft sealing ring has now been removed.

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Version with inner securing ring: 12. Remove the inner securing ring.

SVIL13COM0059AB

12

SVIL13COM0153AB

13

SVIL13COM0154AB

14

SVIL13COM0155AB

15

13. Fit the ball-head tool into the bearing.

14. Place the housing under the press.

15. Insert the attachment into the vent bore.

16. Press the bearing out of the housing.

17. The vibro housing has now been dismantled.

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Compaction drums - Assemble Vibro - bearing - flange Pre-assembling the housing 1. Clean the housing (left) with silicone remover.

SVIL13COM0134AB

1

SVIL13COM0067AB

2

SVIL13COM0068AB

3

SVIL13COM0059AB

4

2. Clean the cylindrical roller bearing (1) and place it in the housing.

3. Press the housing (1) and the cylinder roller bearing (2) together.

Version with inner securing ring: 4. Install the inner securing ring.

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5. Coat the A60/95x10 shaft sealing ring with isopropyl alcohol and insert it into the housing.

SVIL13COM0069AB

5

SVIL13COM0070AB

6

SVIL13COM0071AB

7

SVIL13COM0066AB

8

6. Press the shaft sealing ring into the housing.

7. Housing left: no shaft sealing ring Housing right: with shaft sealing ring

Pre-assembling the flange 1. Clean the flange with silicone remover.

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2. Clean the cylindrical roller bearing (1) and place it in the flange.

SVIL13COM0072AB

9

3. Press the flange (1) and the cylinder roller bearing (2) together.

SVIL13COM0073AB

10

SVIL13COM0074AB

11

SVIL13COM0069AB

12

The flange and the cylinder roller bearing have now been assembled.

4. Insert the inner securing ring.

5. Moisten the shaft sealing ring A60/95x10 with isopropyl alcohol and insert it in the flange recess.

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6. Use the disk (1) to fit the shaft sealing ring.

SVIL13COM0112AB

13

SVIL13COM0075AB

14

SVIL13COM0076AB

15

SVIL13COM0077AB

16

7. Press the shaft sealing ring into the flange.

8. Pre-assembled flange

9. Turn the flange over.

10. Remove the inner ring and rub it dry inside.

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Vibro bearing housing 1. Take out the inner bearing ring and rub it dry inside.

NOTICE: Label the inner ring and the bearing. They fit together and must not be mixed up.

SVIL13COM0078AB

17

SVIL13COM0089AB

18

SVIL13COM0173AB

19

SVIL13COM0175AB

20

2. Grease the housing inside with CASE AKCELA GRADE F GEAR LUBE. Total amount of grease for the housing = 60.0 g (2.1 oz).

3. Material: Assembly tool for SpeedySleeve ring LOCTITE® 603™ SpeedySleeve ring

4. Apply LOCTITE® 603™ SpeedySleeve ring.

to

the

inside

of

the

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5. Insert the SpeedySleeve ring into the assembly tool.

SVIL13COM0176AB

21

SVIL13COM0178AB

22

SVIL13COM0177AB

23

SVIL13COM0111AB

24

6. Position the tool on the vibro shaft.

7. Use a nylon hammer and the assembly tool to hammer the SpeedySleeve ring into position.

NOTE: The tool determines the position of the ring.

8. Mounted SpeedySleeve ring

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9. Attach the temperature sensor to the inner ring.

10. Heat the inner ring to 110 °C (230 °F) The value is pre-defined by the “Bearing” symbol (1).

SVIL13COM0079AB

25

SVIL13COM0080AB

26

SVIL13COM0114AB

27

SVIL13COM0081AB

28

11. Push the inner ring of the flange bearing onto the vibro shaft (vibromotor side).

NOTICE: The rim of the inner ring must face towards the shaft when pushed on.

12. Push the inner ring of the bearing housing onto the rear of the vibro shaft (drive motor side).

13. Unscrew the threaded pin with hexagon socket from the hub with an Allen key.

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14. Attach the temperature sensor to the hub.

15. Heat the hub to 120 °C (248 °F).

SVIL13COM0082AB

29

SVIL13COM0083AB

30

SVIL13COM0115AB

31

SVIL13COM0162AB

32

16. Grease the end of the shaft.

17. Attach the hub.

18. Fill LOCTITE® 242® into the threaded hole.

19. Tighten the screw with an Allen key.

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20. Place the shaft sealing ring (1) in the clamp ring (2).

NOTICE: Place the sealing lip facing the drive bearing!

SVIL13COM0084AB

33

SVIL13COM0113AB

34

SVIL13COM0085AB

35

SVIL13COM0086AB

36

21. Press the shaft sealing ring in with help of the installation plate.

22. Press the shaft sealing ring into the clamp ring.

23. Grease the X-ring (1) and the nut.

24. Place the X-ring (1) in the clamp ring and press it firmly into place.

Next operation: Install the drum. Refer to Compaction drums - Install (44.160).

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Install the wheel support on the drive motor side. Refer to Travel motor - Install Wheel - support (35.353) Next operation: Install the wheel support on the vibromotor side. Refer to Compaction/vibration motor - Install Wheel - support (35.995)

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Compaction drums - Replace the rubber element NOTE: The procedure for the front drum and the rear drum is the same.

If a rubber element has cracks that are deeper than 10 mm (0.39 in), it will need to be replaced.

1.

Remove the rubber elements.

2.

Use LOCTITE® 242® and a torque of 210 N·m (155 lb ft) to install the new rubber elements.

NOTICE: The rubber element will prematurely wear out if a gap exists between the rubber element and the holder.

Install a specially designed shim (slotted washer) to eliminate the gap. The design of the shim allows for installation without having to disassemble the drum components. Simply loosen the bolt enough to slide the shim into place and reset the nut torque.

SVIL13COM0062AB

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1

Wheels - Compaction drums

Compaction rear drum shaft - Disassemble NOTE: The procedure for the front drum and the rear drum is the same.

NOTICE: The vibro shaft needs to be disassembled if: The eccentrics are seizing.

The spring bushings are loose or damaged.

The eccentric assemblies have excessive play at the shaft.

The key seats are worn out.

The SpeedySleeve ring is loose or damaged.

The bearing seat of the self-aligning bearing is damaged.

Clamp the vibro shaft in a vise.

Make sure the key seats are facing upward.

SVIL13COM0200AB

1

SVIL13COM0593AB

2

SVIL13COM0594AB

3

1. Heat up the left-hand and right-hand SpeedySleeve rings to an approximate temperature of 180 °C (356 °F).

2. Pull the SpeedySleeve rings off the shaft.

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3. Remove the feather key from the pinion.

SVIL13COM0227AB

4

SVIL13COM0228AB

5

SVIL13COM0226AB

6

SVIL13COM0219AB

7

4. Remove the bearing from the shaft.

5. Remove the SpeedySleeve ring.

6. Remove the nut by using an Allen wrench.

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7. Remove the hexagon nut.

SVIL13COM0218AB

8

SVIL13COM0215AB

9

8. Remove the shoulder screws on both sides.

9. Remove the spring bushings on both sides.

SVIL13COM0216AB

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10

Wheels - Compaction drums

10. Remove the outer securing rings.

11. Remove the eccentrics from the shaft on both side.

SVIL13COM0213AB

11

SVIL13COM0212AB

12

SVIL13COM0211AB

13

SVIL13COM0210AB

14

12. Remove the feather keys on both keys.

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13. Remove the spacer rings on both sides.

SVIL13COM0208AB

15

SVIL13COM0209AB

16

SVIL13COM0205AB

17

14. Remove the pre-assembled left-hand and right-hand eccentrics from the shaft.

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15. Remove the spacer rings on both sides.

SVIL13COM0207AB

18

SVIL13COM0206AB

19

SVIL13COM0202AB

20

SVIL13COM0201AB

21

16. Remove the eccentrics from the shaft on both sides.

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17. Press out the bearing bushing.

SVIL13COM0204AB

22

SVIL13COM0203AB

23

SVIL13COM0200AB

24

18. Remove the bearing bushing from the eccentric.

19. Remove the feather keys (1) from the inner key seats.

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Compaction rear drum shaft - Assemble NOTE: The procedure for the front drum and the rear drum is the same.

1. Clamp the vibro shaft in a vise.

Make sure the key seats are facing upward.

2. Insert the feather keys into the inner key seats.

SVIL13COM0200AB

1

SVIL13COM0203AB

2

SVIL13COM0204AB

3

3. Loosely place the bearing bushing on the eccentric.

4. Press the bearing bushing in.

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5. Slide the eccentrics onto the shaft on both sides.

SVIL13COM0201AB

4

SVIL13COM0202AB

5

SVIL13COM0637AB

6

6. Use the alignment notches (1) as a guide.

7. Let the feather keys (2) face upward.

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8. Mount the spacer rings on both sides.

SVIL13COM0206AB

7

SVIL13COM0207AB

8

SVIL13COM0205AB

9

9. Slide the pre-assembled left-hand and right-hand eccentrics onto the shaft.

NOTICE: The eccentrics must be dry when mounted – do not grease them!

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10. Mount the spacer rings on both sides.

SVIL13COM0209AB

10

SVIL13COM0208AB

11

SVIL13COM0210AB

12

SVIL13COM0211AB

13

11. Insert the feather keys on both keys.

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12. Slide the eccentrics tightly onto the shaft on both side.

13. Secure them with the outer securing rings.

SVIL13COM0212AB

14

SVIL13COM0213AB

15

SVIL13COM0214AB

16

14. Spring bushing assembly kit

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15. Insert the spring bushings on both sides.

16. Install the shoulder screws on both sides.

SVIL13COM0216AB

17

SVIL13COM0215AB

18

SVIL13COM0217AB

19

SVIL13COM0218AB

20

17. Apply LOCTITE® 242® to the thread.

18. Attach the hexagon nut.

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19. Torque the nut to 16 N·m (11.8 lb ft). Use an Allen wrench) to hold the assembly on the other side.

NOTE: Check the loose eccentrics to make sure they move easily. They must turn all the way to the stop clockwise and counterclockwise.

SVIL13COM0219AB

21

SVIL13COM0223AB

22

SVIL13COM0222AB

23

SVIL13COM0220AB

24

20. Insert clean SpeedySleeve rings in the assembly tool.

NOTE: The assembly tools for the left-hand side and righthand side are different from each other.

21. Grease the shaft (clean).

22. Uniformly apply LOCTITE® 603™ to the bearing seats (on the shaft) for the left-hand side and right-hand side SpeedySleeve rings.

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23. Hammer the SpeedySleeve rings onto the shaft on both sides.

SVIL13COM0225AB

25

SVIL13COM0224AB

26

SVIL13COM0221AB

27

SVIL13COM0226AB

28

24. Mounted SpeedySleeve ring

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25. Check the left–hand side and right-hand side bearing seats on the vibro shaft: A. Lightly grease the seat.

B. It must be possible to slide the bearing over the shaft (sliding fit!)

SVIL13COM0228AB

29

SVIL13COM0227AB

30

26. Insert the feather key for the pinion.

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Compaction rear drum shaft - Disassemble DV23 DV26

NOTE: The procedure for the front drum and the rear drum is the same.

NOTICE: The vibro shaft needs to be disassembled if: The eccentrics are seizing.

The spring bushings are loose or damaged.

The eccentric assemblies have excessive play at the shaft.

The key seats are worn out.

The SpeedySleeve ring is loose or damaged.

The bearing seat of the self-aligning bearing is damaged.

Clamp the vibro shaft in a vise.

Make sure the key seats are facing upward.

SVIL13COM0200AB

1

SVIL13COM0593AB

2

SVIL13COM0594AB

3

1. Heat up the left-hand and right-hand SpeedySleeve rings to an approximate temperature of 180 °C (356 °F).

2. Pull the SpeedySleeve rings off the shaft.

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3. Remove the feather key from the pinion.

SVIL13COM0227AB

4

SVIL13COM0228AB

5

SVIL13COM0226AB

6

SVIL13COM0219AB

7

4. Remove the bearing from the shaft.

5. Remove the SpeedySleeve ring.

6. Remove the nut by using an Allen wrench.

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7. Remove the hexagon nut.

SVIL13COM0218AB

8

SVIL13COM0215AB

9

8. Remove the shoulder screws on both sides.

9. Remove the spring bushings on both sides.

SVIL13COM0216AB

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10

Wheels - Compaction drums

10. Remove the outer securing rings.

11. Remove the eccentrics from the shaft on both side.

SVIL13COM0213AB

11

SVIL13COM0212AB

12

SVIL13COM0211AB

13

SVIL13COM0210AB

14

12. Remove the feather keys on both keys.

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13. Remove the spacer rings on both sides.

SVIL13COM0208AB

15

SVIL13COM0209AB

16

SVIL13COM0205AB

17

14. Remove the pre-assembled left-hand and right-hand eccentrics from the shaft.

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15. Remove the spacer rings on both sides.

SVIL13COM0207AB

18

SVIL13COM0206AB

19

SVIL13COM0202AB

20

SVIL13COM0201AB

21

16. Remove the eccentrics from the shaft on both sides.

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17. Press out the bearing bushing.

SVIL13COM0204AB

22

SVIL13COM0203AB

23

SVIL13COM0200AB

24

18. Remove the bearing bushing from the eccentric.

19. Remove the feather keys (1) from the inner key seats.

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Compaction rear drum shaft - Assemble DV23 DV26

NOTE: The procedure for the front drum and the rear drum is the same.

1. Clamp the vibro shaft in a vise.

Make sure the key seats are facing upward.

2. Insert the feather keys into the inner key seats.

SVIL13COM0200AB

1

SVIL13COM0203AB

2

SVIL13COM0204AB

3

3. Loosely place the bearing bushing on the eccentric.

4. Press the bearing bushing in.

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5. Slide the eccentrics onto the shaft on both sides.

SVIL13COM0201AB

4

SVIL13COM0202AB

5

SVIL13COM0637AB

6

6. Use the alignment notches (1) as a guide.

7. Let the feather keys (2) face upward.

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8. Mount the spacer rings on both sides.

SVIL13COM0206AB

7

SVIL13COM0207AB

8

SVIL13COM0205AB

9

9. Slide the pre-assembled left-hand and right-hand eccentrics onto the shaft.

NOTICE: The eccentrics must be dry when mounted – do not grease them!

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10. Mount the spacer rings on both sides.

SVIL13COM0209AB

10

SVIL13COM0208AB

11

SVIL13COM0210AB

12

SVIL13COM0211AB

13

11. Insert the feather keys on both keys.

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12. Slide the eccentrics tightly onto the shaft on both side.

13. Secure them with the outer securing rings.

SVIL13COM0212AB

14

SVIL13COM0213AB

15

SVIL13COM0214AB

16

14. Spring bushing assembly kit

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15. Insert the spring bushings on both sides.

16. Install the shoulder screws on both sides.

SVIL13COM0216AB

17

SVIL13COM0215AB

18

SVIL13COM0217AB

19

SVIL13COM0218AB

20

17. Apply LOCTITE® 242® to the thread.

18. Attach the hexagon nut.

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19. Torque the nut to 16 N·m (11.8 lb ft). Use an Allen wrench) to hold the assembly on the other side.

NOTE: Check the loose eccentrics to make sure they move easily. They must turn all the way to the stop clockwise and counterclockwise.

SVIL13COM0219AB

21

SVIL13COM0223AB

22

SVIL13COM0222AB

23

SVIL13COM0220AB

24

20. Insert clean SpeedySleeve rings in the assembly tool.

NOTE: The assembly tools for the left-hand side and righthand side are different from each other.

21. Grease the shaft (clean).

22. Uniformly apply LOCTITE® 603™ to the bearing seats (on the shaft) for the left-hand side and right-hand side SpeedySleeve rings.

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23. Hammer the SpeedySleeve rings onto the shaft on both sides.

SVIL13COM0225AB

25

SVIL13COM0224AB

26

SVIL13COM0221AB

27

SVIL13COM0226AB

28

24. Mounted SpeedySleeve ring

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25. Check the left–hand side and right-hand side bearing seats on the vibro shaft: A. Lightly grease the seat.

B. It must be possible to slide the bearing over the shaft (sliding fit!)

SVIL13COM0228AB

29

SVIL13COM0227AB

30

26. Insert the feather key for the pinion.

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Index Wheels - 44 Compaction drums - 160 Compaction drums - Assemble Drive - bearing - flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

Compaction drums - Assemble Vibro - bearing - flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36

Compaction drums - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Compaction drums - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Compaction drums - Disassemble Drive - bearing - flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

Compaction drums - Disassemble Vibro - bearing - flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32

Compaction drums - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

Compaction drums - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Compaction drums - Replace the rubber element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46

Compaction rear drum shaft - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54

Compaction rear drum shaft - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70

Compaction rear drum shaft - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47

Compaction rear drum shaft - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63

(*) See content for specific models 48142067 15/09/2017

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404

SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. Š 2017 CNH Industrial America LLC. All rights reserved.

No part of the text or illustrations of this publication may be reproduced.

CNH Industrial America LLC reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at the time of publication, but are subject to change without notice.

Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your CASE CONSTRUCTION dealer.

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

Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.

48142067 15/09/2017 EN

SERVICE MANUAL Electrical systems DV23CC DV23 DV26CC DV26

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Contents Electrical systems - 55

[55.031] Parking brake electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.019] Hydrostatic drive control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 [55.404] External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8 [55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9

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Electrical systems - 55 Parking brake electrical system - 031

DV23CC DV23 DV26CC DV26

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Contents Electrical systems - 55 Parking brake electrical system - 031

SERVICE Brake control solenoid Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Brake control solenoid - Check Locate the brake valve solenoid (1).

SVIL13COM0339AB

1

SVIL13COM0370AB

2

SVIL13COM0372AB

3

SVIL13COM0374AB

4

1. Remove the solenoid.

2. Remove the solenoid valve.

NOTE: Make sure not to exceed a torque of 40 N·m (29.5 lb ft) when reinstalling the valve.

3. Disassembled solenoid valve.

• Nut (1) • Gasket (2) • Solenoid (3) • Solenoid valve (4)

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4. Apply a voltage of 12 V to the solenoid valve.

5. The valve must be visibly and audibly actuated.

6. Check the gaskets (1) for damage.

SVIL13COM0376AB

5

SVIL13COM0368AB

6

7. Measure the solenoid’s resistance.

The value should be 5 Ί.

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Index Electrical systems - 55 Parking brake electrical system - 031 Brake control solenoid - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Electrical systems - 55 Electrical system - 000

DV23CC DV23 DV26CC DV26

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Contents Electrical systems - 55 Electrical system - 000

FUNCTIONAL DATA Electrical system Component identification - Software and hardware (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Fault code index - Diagnosis troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Electrical system Connect - Diagnosis hardware to the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Configure - BODAS service (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Connect - BODAS service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Check - Basic information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Check - Process data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Check - Error memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Adjust - Editing controller parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Adjust - Editing ramp mode parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Remove - Deleting error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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Electrical system - Component identification - Software and hardware (optional) NOTE: The BODAS system is only an option and not a requirement. Please call your technical support, if the BODAS system is desired.

Features The BODAS-service PC software tool provides a convenient and user-friendly method of executing service functions for BODAS controllers from Rexroth. Parameters could be displayed and edited, process variables displayed, and their values graphically plotted and recorded. In addition, error messages could be read out, reset as well as the application´s diagnostic configuration configured. Furthermore, functions are available for reading out and writing to the controller EEPROM. For BODAS controllers, equipped with CAN diagnosis, extensive version information on the controller is displayed.

For these controllers, in the event of an emergency, full access to all process variables and parameters is possible for a single service session via an "Emergency Access" (requires only the BODAS-service DEMO version).

BODAS-service also offers an option for the loading of application software, so-called HexFiles, onto BODAS controller RC and the transfer of display configuration Files onto the BODAS Display DI3.

The respective functions are enabled by a USB hardlock (license control).

BODAS-service contains BODEM 25 and FT2 (Not available from Windows 7).

The following license versions can be selected: • BODAS-service Diagnosis (contains BODEM25 license) • BODAS-service Flash Tool • BODAS-service Full Version (contains BODEM25 license) All of the listed functions can be executed on a PC or laptop.

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Function/operating notes The BODAS-service PC software tool provides a convenient and user-friendly method of executing service functions for BODAS controllers from Rexroth. Depending on the license version which is purchased, the tool is characterized by the following functions: • Extremely user-friendly, through Windows user interface, free configurable work flow and online help • Simultaneous display of multiple parameters for modification settings • Simultaneous display of multiple process variables in graphical or numeric form • Printout of all settings and process variables for documentation purposes • Clear and easy-to-understand display of error messages • Easy-to-use data logger: Save measured values (process variables and parameters) to the hard disk • Selectable and expandable program language • Adjustable device language (relevant to controller data, up to 4 languages available) • Diagnosis Configuration for a BODAS or C application on BODAS controller RC • Transfer software from PC to a BODAS controller RC (flashing of application software) • Transfer of Display configuration Files onto BODAS Display DI3.

• Save the data contained in the EEPROM of a BODAS controller or transfer an EEPROM file (EPR file) to a BODAS controller • Command line control option for various BODAS functions, e-g flash programming or EPR file download Additional functions for BODAS controller RC beginning with CAN diagnosis: • Display of extensive version information • Emergency release of all parameters and process variables via an "Emergency Access" (beginning with the BODAS‑service DEMO version) for a one-time connection by means of the "Seed and Key" process NOTE: A Demo version of BODAS-service 3.x – capable of displaying data only – is available as a free download on the Internet at www.boschrexroth.com/mobile-electronics under the header "BODAS-Tools" or within the Rexroth media directory at the search criteria "Diagnosis Tool BODAS-service". The demo version does not allow to modify, save or delete any parameters or data.

Notebook All current models with CD-ROM and min. 2x USB connections should work.

Microsoft windows (XP, Vista or 7) is, however, required.

NOTE: For Windows 7, you may need to download the latest drivers from manufacturer websites.

SS12K423

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Adapter cable CAN-to-USB adapter

SS12K424

2

SS12K425

3

SS12K426

4

CAN bus USB adapter Interface/port converter Install the enclosed driver before connecting the device.

NOTE: You will find the latest drivers at: www.peak-system.com /Products/CAN-interfaces/PCANUSB.

BODAS service software Install the enclosed driver before connecting the device.

NOTE: The enclosed USB dongle works with all versions of BODAS Service 3.x.

We recommend downloading the latest version: www.boschrexroth.com/Products/Mobile Hydraulics/Mobile Electronics/BODAS Tools.

NOTE: These instructions were written for BODAS version 3.3 Newer or older versions may differ in use.

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Electrical system - Fault code index - Diagnosis troubleshooting Fault description A message is displayed due to missing licence key.

Remedy 1. Connect the USB dongle from Bosch Rexroth to your computer.

2. Make sure that your computers USB ports are working.

SS12K439

1

1. Connect the CAN bus USB adapter to your computer.

No CAN-USB adapter found.

2. Make sure that your computers USB ports are working.

3. Make sure that Interface configuration was performed as described.

SS12K440

2

Search for BODAS controllers found nothing.

1. Connect the CAN bus USB adapter to the machine using the adapter cable.

2. Switch on the ignition on the machine.

3. Check the adapter cable connectors.

4. Make sure that BODAS Service settings were configured as described.

SS12K441

3

Although the BODAS controller is found, data transfer is 1. If not absolutely necessary, perform diagnosis while incomplete or the connection is lost again after a short the diesel engine is stopped. time.

2. Check the CAN bus USB adapter connectors for loose connections.

3. Reboot the notebook and switch the ignition off and back on the machine.

NOTE: If the multifunction unit displays a BUS error, there is probably a problem with the machine wiring.

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Electrical system - Connect - Diagnosis hardware to the machine 1. Remove the cover (1) on the steering column.

SS12K220

1

SS12K427

2

SS12K428

3

2. Connect the adapter cable (1) to connector X7 (2).

3. Connect the CAN bus USB adapter (1).

Connect the USB dongle (2).

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4. Turn on the laptop and run the BODAS-service application. Accept the license agreement.

RAIL17COM0493BA

Next operation: Electrical system - Configure - BODAS service (Option) (55.000).

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Electrical system - Configure - BODAS service (Option) NOTE: The BODAS software is only an option and not required.

After launching BODAS service, make sure that the settings in application options (1) and interface configuration (2) are as follows.

SS12K429

1

SS12K430

2

Application option

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Interface configuration

SS12K431

3

Next operation: Electrical system - Connect - BODAS service (55.000).

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Electrical system - Connect - BODAS service 1. Turn the ignition switch to position I. NOTE: You can perform diagnosis with the diesel engine running or stopped.

SS12K432

1

RAIL17COM0494FA

2

RAIL17COM0495FA

3

2. Start the search for BODAS controllers.

3. In the BODAS-service app, click on the magnifying glass (Scan for controllers). The laptop will connect to the control unit of the machine.

4. The connection is successful if there is a green symbol next to the control unit name.

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Electrical system - Check - Basic information

SS12K435

1

Once a connection has been made, first you will see general information about the controller. You can display this screen at any time again by clicking on the top line but one in the list on the left.

Operating hours counter (1) The operating hours of the controller are displayed.

This figure does not match the operating hours displayed on the multifunction device.

Officially, the hours displayed on the multifunction device apply.

Program version (2) The version of the program is displayed in the form ACH100 Vx.xx.

NOTE: These instructions refer to version 1.17.

Default values (3) / Save (4) This function resets all parameters to their default values. To do so, first click button (3) to reset the parameters and then button (4) to save.

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Electrical system - Check - Process data

SS12K436

1

Processdata/All Processdata displays a list of process data. The list includes the states of all inputs and outputs. The list is refreshed automatically. All changes are displayed after approximate 1 s.

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Number 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 3.8 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 5.1 5.2 5.3 5.4 5.5

Designation Operating lever left Operating lever neutral switch, left Operating lever right Operating lever neutral switch, right Sprinkler potentiometer Vibration button Automatic vibration Work speed Seat contact Brake pressure sensor Parking brake switch Calibration Oil temperature Diesel speed Asphalt temperature Rear vibration on Drive pump, forwards Drive pump, backwards Vibration relay Brake valve Sprinkler relay Reverse alarm Brake pressure display Oil temperature Warning buzzer Error lamp Hydraulic oil cooler Brake-light Operating hours pump on Operating hours vibration on Brake pressure sensor counter

5.6 5.7

Parking brake counter Seat contact counter

5.8

Element/Description S15 (optional) S15 (optional) S3 S3 S5 S4/S16 S7 S6 S51 S52 S17 X8 S53 Speed signal from alternator G1 N3 (optional) S8 (DV36 and DV45 only) Y3 Y4 K4 Y2 K6 B11 H9 H5 B13 (optional) H1 K5 K17, E25, E26 (optional) No function No function Counts how many times the brake pressure sensor S52 has changed state during travel (loose connection).

Counts how many times the parking brake was activated during travel (operating error).

Counts how many times the seat contact switch S51 has changed state during travel (loose connection or operating error).

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Electrical system - Check - Error memory

SS12K437

1

You can find error memory in Diagnosis/Error messages.

Pending errors (1) and errors in memory (2) are displayed.

Meaning Serial number with no meaning Can provide additional information about the error (refer to the fault codes list).

Indicates how many times the error has occurred.

Time stamp of the last occurrence of the error.

Name of the error (refer to the fault codes list) No meaning

Column name Index Error code Occurrences Timestamp Error message Param You can delete the error list by pressing buttons (3) and (4).

NOTE: Only delete the error list if you know what you are doing. There is no point in deleting errors before the cause has been fixed.

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Electrical system - Adjust - Editing controller parameters

SS12K438

1

You can modify the controller using parameters. Select Parameter/Parameter display/edit to display lists of editable parameters.

After changing any parameters, click button (1) to save them.

You can reset single parameters to their default values by pressing the STD button (2). Click button (1) to save them.

NOTICE: Note that inexpertly modification parameters may lead to unintended machine behavior.

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Calibration Pos. 1.1.1 1.1.2 1.1.3 1.1.4 1.1.5

Designation Operating lever left Operating lever left, central position Operating lever right Operating lever right, central position Sprinkling (Option; not available in NA)

NOTE: Calibration is not necessary for the integrated operating levers and therefore should not be used.

Allows you to calibrate the sprinkler potentiometer. Detects both end positions.

Seat contact delay

NOTE: Calibration is not necessary for the integrated potentiometer and therefore should not be used.

Defines the delay for the seat contact switch.

Pump current balance

NOTE: The value must not be greater than 1 s if no seat contact warning buzzer is installed (option).

Using this function you can activate calibration mode without having to jumper connector X8.

1.1.6

1.1.7

Description Allows you to calibrate the operating lever. Detects end positions and central position.

NOTE: This parameter must be reset after use.

Drive Pos.

Designation Work speed

1.2.1

Description Specifies work speed in per cent of transport speed (approximate 10 km/h (6.2 mph)).

NOTE: A large value may lead to performance problems on upward slopes.

Vibration Pos. 1.7.1 1.7.2

Designation Description Automatic off on These parameters can be used to optimize the switch-on and switch-off point pump of the automatic vibration function.

Automatic hysteresis To do so, first set the desired switch-off point in parameter 1.7.1 and then configure how much later you want vibration to switch on parameter 1.7.2 You can test the settings and adjust them again as required.

Temperature Pos. 2.1.7

Designation Unit

Description Specifies the unit (°C or °F) for asphalt temperature (option) display.

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Electrical system - Adjust - Editing ramp mode parameters 1. Go to the Parameter menu (1). Choose 1.2. Drive Control submenu (2).

RAIL17COM0497FA

1

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2. Click the blank square (1) in section 1.2.4. WorkMode same as TransportMode submenu - value in the status window changes from 0 to 1 (2).

RAIL17COM0498FA

2

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3. Click on Save (1), then confirm by clicking on OK (2).

RAIL17COM0499FA

3

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Electrical system - Remove - Deleting error messages

RAIL17COM0500FA

1

1. Click on the Error Messages menu (1).

2. To delete an active error, click on the Delete active errors button (2). To delete saved errors click on Delete saved errors button (3).

3. After deleting errors restart the connection between laptop and the control unit.

4. Click again on magnifier icon (Scan).

5. Click again on the Error Messages menu. If there are any error messages, it is necessary to repair the defect before using the machine again.

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Index Electrical systems - 55 Electrical system - 000 Electrical system - Adjust - Editing ramp mode parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

Electrical system - Adjust - Editing controller parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

Electrical system - Check - Basic information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

Electrical system - Check - Error memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

Electrical system - Check - Process data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

Electrical system - Component identification - Software and hardware (optional) . . . . . . . . . . . . . . . .

3

Electrical system - Configure - BODAS service (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Electrical system - Connect - BODAS service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Electrical system - Connect - Diagnosis hardware to the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Electrical system - Fault code index - Diagnosis troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Electrical system - Remove - Deleting error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

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Electrical systems - 55 Hydrostatic drive control system - 019

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Contents Electrical systems - 55 Hydrostatic drive control system - 019

SERVICE Hydrostatic drive control system Adjust Pump current calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Check Drive pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Hydrostatic drive control system - Adjust Pump current calibration Pump current calibration can help with the following problems: • The machine displays severe jolting on stopping/ starting. • The machine stops for a long time when changing direction.

NOTE: Only perform the following procedure if you think it is absolutely necessary.

NOTICE: If calibration is not performed properly, this may even cause deteriorated driving behavior.

1. Position the machine on a level, tarmacked surface.

Make sure that there is no upward or downward slope.

NOTE: It is recommended to calibrate the machine only after it has reached its operating temperature.

SS12K212

1

SS12K213

2

2. Remove the cover (1) on the steering column.

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3. Switch the ignition off (1) and switch it on (2) again.

Start the engine (3).

SS12K214

3

SS12K215

4

SS12K216

5

4. Jumper the two contacts of X8.

The braking indicator now starts to flash on the display unit.

The machine is now in calibration mode.

NOTE: Make sure that the parking brake is not engaged.

NOTE: You can also use a piece of wire as a makeshift.

5. Accelerate the machine to full speed.

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6. Move the operating lever (1) very slowly out of middle position.

SS12K217

6

SS12K218

7

SS13A395

8

7. Once the machine begins to move, press the vibration button briefly (2).

NOTE: The operating lever must be moved out further than usual in this mode until the machine begins to move.

NOTE: The display unit now displays the newly calibrated current value for a short time.

The value should be in the range of 370 – 430 bar (5365.00 – 6235.00 psi). If it differs severely from this range, there may be a hydraulic or mechanical problem.

8. Repeat the procedure for the other direction of travel.

9. Remove the jumper on X8.

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Electrical systems - Hydrostatic drive control system

Hydrostatic drive control system - Check Drive pressure It is possible to drive the vehicle drive against the engaged brakes.

Although this is prevented in normal operation, it can be activated by the connector X8.

NOTE: Only perform the following procedure if you think it is absolutely necessary.

NOTICE: This puts a heavy mechanical and hydraulic load on the machine. Ensure adequate safety clearance in front of, behind and alongside the machine.

1. Remove the cover (1) on the steering column.

SS12K220

1

SS12K214

2

2. Switch the ignition off (1) and switch it on (2) again.

Start the engine (3).

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Electrical systems - Hydrostatic drive control system

3. Jumper the two contacts of X8.

NOTE: You can also use a piece of wire as a makeshift.

SS12K421

3

SS12K422

4

4. Engage the parking brake by pressing switch S17 (1).

The braking indicator now lights up solid on the display unit.

You can drive the machine against the brake.

5. To quit this mode, remove the jumper on X8.

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Index Electrical systems - 55 Hydrostatic drive control system - 019 Hydrostatic drive control system - Adjust Pump current calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Hydrostatic drive control system - Check Drive pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

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Electrical systems - 55 Harnesses and connectors - 100

DV23CC DV23 DV26CC DV26

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Contents Electrical systems - 55 Harnesses and connectors - 100

FUNCTIONAL DATA Wiring harnesses Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Electrical schematic sheet 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Electrical schematic sheet 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Wire connectors Component localization - Connector X50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Fuse and relay box Component localization - Steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Component identification - Steering column pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Component localization - Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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Electrical systems - Harnesses and connectors

Wiring harnesses - Component identification

SS13A875

Pos.

1

2 3 4

Designation Element name (refer to Wiring harnesses - Electrical schematic sheet 01 (55.100) and Wiring harnesses - Electrical schematic sheet 02 (55.100)) Connection Connector name

1

Pos.

5

6 7

Designation Cable number All white cables are serially numbered, the brown cables are not numbered and are always a connection to earth.

Contact number on device connector Component separation (In some cases also optional cable connections)

Contact number

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 01 Pos. B11 B13 E25 E26 F9 F10 F11 F13 F14 F15 F21 F22 G1 G2 H1 H2 H5 H6 H8 H9 K2 K3 K4 K5 K6 K7 K12 K17 M1 M2 M3 M4 M11

Designation Reverse alarm Warning buzzer, seat contact delay Right brake-light Left brake-light Fuse, controller, supply Fuse, controller, outputs Fuse, sprinkler Fuse - vibration Fuse, controller, inputs Fuse, hydraulic oil cooler Fuse, starter Fuse, diesel pump, alternator Alternator Battery Warning lamp, error Control lamp, charging control Warning lamp, hydraulic oil temperature Warning lamp, emergency stop Control lamp, preheating Control lamp, brake pressure Timer relay Relay, pull-in solenoid Relay, vibration Relay, hydraulic oil cooler Relay, sprinkler Relay, starting interlock Relay, anti-adhesive sprinkler Relay, brake-light Starter motor Hydraulic oil cooler Diesel pump Sprinkler pump Sprinkler pump, anti-adhesive

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Comments Option Option Option Option

Option (not available in NA) Option

Option (not available in NA)

Electrical systems - Harnesses and connectors

Pos. N1 N2 N3 P1 R1 S1 S2 S3 S4 S5 S6 S7 S8 S15 S16 S17 S18 S51 S52 S53 Y1 Y2 Y3 Y4 Y5 Y6 Y9

Designation Controller Display unit Measuring transducer, asphalt temperature Operating hours counter Preheating coil Switch, ignition Switch, emergency stop Operating lever sensor, right Operating lever switch, right Potentiometer, sprinkler Switch, work gear Switch, vibration automation Switch, rear vibration Operating lever sensor, left Operating lever switch, left Switch, parking brake Battery cutoff switch Sensor, seat contact Sensor, brake pressure Sensor, hydraulic oil temperature Pull-in/holding solenoid Valve, locking brake Drive pump, forwards Drive pump, backwards Valve, front vibration Valve, rear vibration Shutoff valve, sprinkler pump

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Comments

Option

Option Option Option

Electrical systems - Harnesses and connectors

RAIL13COM0024JA

1

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 02 Pos. A1 B1 B12 E1 E2 E3 E11 E12 E13 E14 E15 E16 E17 E18 E19 E20 E21 E22 E23 E24 F1 F2 F3 F4 F5 F6 F7 F8 F12 H3 H4 H7 H10 H11 H12 K11 K13 K14

Designation Fuel level display, diesel tank Horn Warning buzzer, flow divider Front right dipped light Front left dipped light Work light rear Front right parking light Front right position light Front left parking light Front left position light Rear right parking light Rear left parking light Front right indicator Front left indicator Rear right indicator Rear left indicator Revolving warning light License plate illumination Work light ROPS Work light ROPS Fuse, hazard flasher Fuse, parking light 1 Fuse, parking light 2 Dipped light fuse Fuse, revolving warning light, work light Fuse, horn Fuse, display unit, reverse alarm, blinker Fuse, Seat heating Fuse, flow divider, edge cutter Warning lamp - engine oil pressure Warning lamp - coolant temperature Warning lamp, diesel reserve Control lamp, parking lights Control lamp, dipped lights Control lamp, blinker Relay, blinker Relay, edge cutter Relay, light

Pos. N2 R11 S9 S10 S11 S12 S13 S19 S20 S21 S22 S54 S55 S56 V11 V12 V13 Y5 Y11 Y12 Y13 Y14

Comments

Option Option Option Option Option Option Option Option Option Option Option Option Option Option Option

Option (not available in NA)

Option Option (not available in NA) Option

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Designation Display unit Seat heating Switch, horn Switch, parking light/dipped light Switch, revolving warning light, work light Switch, hazard flasher Switch indicator Switch, flow divider Switch, edge cutter, up Switch, edge cutter, down Switch, edge cutter, water Sensor, diesel tank Sensor, engine oil pressure Sensor, coolant temperature Free-running diode, buzzer, flow divider Free-wheeling diode, edge cutter 1 Free-wheeling diode, edge cutter 2 Valve, front vibration Valve flow divider Valve, edge cutter up Valve, edge cutter down Valve, edge cutter water

Comments

Option Option Option Option Option (not available in NA) Option (not available in NA) Option (not available in NA)

Option Option (not available in NA) Option (not available in NA)

Option (not available in NA) Option (not available in NA) Option (not available in NA)

Electrical systems - Harnesses and connectors

RAIL13COM0026JA

1

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Electrical systems - Harnesses and connectors

Wire connectors - Component localization - Connector X50 The connector is located under the floor panel of the driver's position. All operating lever signals are transmitted via this connector.

NOTICE: Make sure that this connector is free of water and dirt.

SS12K205

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1

Electrical systems - Harnesses and connectors

Fuse and relay box - Component localization - Steering column

SS13A876

1

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Electrical systems - Harnesses and connectors

Designation

Pos. K4 K5 K6 K11

Vibration Hydraulic oil cooler Sprinkling (water) (Option; not available in NA) Indicator relay Sprinkling (anti-adhesive) (Option; not available K12 in NA) K14 Parking lights and dipped lights

Pos. X1 X2 X3 X4 X5 X6 X7 X8

Pos. Power F1

10 A

F2

7.5 A

F3

7.5 A

F4

10 A

F5

15 A

F6

7.5 A

F7 F8

10 A 10 A

Designation Connector Connector Connector Connector Connector empty Connector A jumper can be connected. This puts the machine into calibration mode.

Pos. Power

Circuit Hazard warning light

F9

3A

F10

10 A

F11

15 A

F12

10 A

F13

10 A

F14

1A

F15 F16

25 A 15 A

Parking light, front right, rear left

Parking light, front left, rear right Work light Beacon lamp, work light Horn Display unit, blinker, reverse alarm Seat heating (X12)

Circuit Machine controller, drive, brake valve, diesel engine holding coil, controller for relay K4 (vibration) Machine controller, drive, brake valve, diesel engine holding coil, controller for relay K4 (vibration) Sprinkling (water and anti-adhesive) (Option; not available in NA) Flow divider, edge cutter (Option; not available in NA) Vibration Brake pressure switch, asphalt temperature sensor Hydraulic oil cooler Reserve

NOTE: Before replacing fuses, always determine and remedy the cause of the fault first.

NOTICE: Always replace a defective fuse with a working fuse of the same amperage (in accordance with the label).

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Electrical systems - Harnesses and connectors

Fuse and relay box - Component identification - Steering column pinout

SS13A396

1

Pos. Designation K4, K5, K6, The relays have the same pinout.

K12, K14 K11 Indicator relay X2, X3, X4 The connectors cannot be mixed up with each other. The chassis wiring harness contains a code for this purpose.

X6 This socket is empty.

X7 The adapter cable for diagnosis can be connected to X7.

X8 A jumper can be connected to X8. This puts the machine into calibration mode. Refer to Hydrostatic drive control system - Adjust Pump current calibration (55.019).

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Electrical systems - Harnesses and connectors

Fuse and relay box - Component localization - Engine Pos. F21 F22 F23 F24 K2 K3 K7

Designation Pull-in solenoid 40 A Diesel pump, alternator 10 A Reserve 10 A Timer 0.5 s Relay, pull-in solenoid Relay, starting interlock

NOTE: (K2) is located on the back of the metal sheet.

SS12K199

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1

Index Electrical systems - 55 Harnesses and connectors - 100 Wiring harnesses - Electrical schematic sheet 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

Fuse and relay box - Component identification - Steering column pinout . . . . . . . . . . . . . . . . . . . . . . .

14

Fuse and relay box - Component localization - Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

Fuse and relay box - Component localization - Steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

Wire connectors - Component localization - Connector X50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Wiring harnesses - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Wiring harnesses - Electrical schematic sheet 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

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

DV23CC DV23 DV26CC DV26

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

FUNCTIONAL DATA Instrument cluster Fault code index Display upon start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Overview ACE force (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

DIAGNOSTIC Warning indicators, alarms, and instruments Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Backup or reverse alarm switch Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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Electrical systems - Warning indicators, alarms, and instruments

Instrument cluster - Fault code index Display upon start-up The current operating state and the errors recognized by the controller are displayed above the hour counter.

If the machine is not in operation, e.g. the seat contact is not closed, the issue preventing start-up will be displayed: Display -11 -12 -13 -14 -15

Error Seat contact open Operating lever is deflected 2 operating levers (optional), both operating levers deflected Parking brake is activated Diesel engine is not running

Remedy Sit down Put the operating lever in the neutral position Put the operating lever in the neutral position Release parking brake Start the engine

NOTE: The display remains blank when the machine is in operation, in other words, when it is being driven and/or is vibrating.

If errors are recognized, the error warning lamp lights in addition to the display of the error code. If more than one error is present, they will be displayed one after the other at an interval of about 5 s.

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Electrical systems - Warning indicators, alarms, and instruments

Instrument cluster - Overview ACE force (option) The ACE force option measure the current stiffness (1) at the front roller drum in kB (Millinewton meter (mN/m)). The display shows the value for stiffness as "cb”. The display also expresses this value graphically in steps of 10 below the numerical value. This measurement starts and stops with the activation of vibration. The values are not saved or printed.

RAIL15COM0101AA

1

Possible displays Display cb 1 ... cb120

cb 000 ... cb 015 cb 888 cb 999

Description Normal operation; the measured compaction value is displayed. Stiffness without a leading “0”; bar graph shows each step of 10 already started.

Calibration mode; status of the calibration procedure.

Calibration mode; calibration error; check the cabling and the machine.

Machine is bouncing; NOTICE: This condition destroys the ground and the roller drum.

It is normal for the display to show "cb 999" briefly during operation, or when you switch vibration on or off. If "cb 999" remains on the display for an extended period of time, the vibration is too strong or the ground is already fully compacted.

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Electrical systems - Warning indicators, alarms, and instruments

Compacting – Stiffness reference values Cold minerals To be able to evaluate the kB values, it is important to know that a sub-grade for a main road or motorway must have a stiffness value up to 100 kB • On a gravel surface, a good stiffness value will be greater than 80 kB. • For gravel layers in a pavement structure or in a frost sub-base, good stiffness values will be between 50 kB and 80 kB. • Expect stiffness values of less than 50 kB after the humus layer is removed from a clayish, very sandy, or wet ground.

Asphalt • Asphalt has a temperature-dependent stiffness. The stiffness increases as the pavement cools.

• It is important that compaction takes place only in the compactible temperature range of 140 – 80 °C (284 – 176 °F).

Regardless of the material (gravel or asphalt, the base layers or paving layers), the increase of the stiffness in kB is an important indicator for compaction tasks. As long as ACE Force detects an increase in stiffness the surface is not at its maximum compaction value. An increase in kB value is always accompanied by an increase of compaction and the load-bearing capacity.

Once you are at the maximum compaction, the kB value will no longer increase and instead have a tendency to decrease. This is the ideal moment to stop compaction. At this point, the material is at its highest possible stiffness.

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Electrical systems - Warning indicators, alarms, and instruments

Calibration If the acceleration sensors have been replaced or the unbalance or the coupling of the vibro shaft have been remounted, it is necessary to calibrate this option. The calibration is performed semi-automatically according to the following description.

Step 1

2 3

4 5

6

7 8 9 10 11 12 13

Description The front roller drum must be placed on old tires so that it can vibrate freely. Only activate the front vibration for the next steps.

Switch off the engine Plug in the calibration dongle. The dongle is different for the various different machine types. The appropriate dongle is attached to the ACE force wiring harness.

Start the engine and set it to full throttle.

The type of the machine is recognized via the dongle and parameters are loaded.

The calibration mode is ready. Switch on the vibration. For the ARX 4, first activate the small amplitude.

Switch on the large amplitude. (Only for the ARX 4) Automatic calibration of the large amplitude The calibration parameters are calculated and saved.

Calibration is complete.

Switch off the engine.

Remove the dongle and reattach it to the wiring harness.

The machine is ready for operation.

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Display

cb 000, cb 001, cb 002

cb 003

cb 004 cb 005 cb 006 ‌ cb 015 cb 000

Electrical systems - Warning indicators, alarms, and instruments

Troubleshooting If no compaction values are displayed when the vibration is switched on, proceed as follows: 1. Check connectors X1 and X7 on the steering column.

2. Check connectors ACE1-4 on the ACE box.

3. Make sure that the calibration dongle is not plugged in.

4. Check sensors S101 (A) and S102 (B) as well as connector X101 (C).

5. Check the wiring against the wiring diagram.

1 2

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Dongle N101

RAIL17COM0042BA

2

RAIL17COM0043BA

3

RAIL17COM0044BA

4

Electrical systems - Warning indicators, alarms, and instruments

RAIL17COM0041FA

5

Wiring diagram

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Electrical systems - Warning indicators, alarms, and instruments

Warning indicators, alarms, and instruments - Troubleshooting Problem Possible Cause Display unit doesn`t work Battery (G2) No lamps and displays when ignition is switched on Fuse (F7) Display unit (N2) Operating hours counter P1 doesn`t work when engine is running.

Battery charge indicator H2 doesn`t go out when engine is running.

Alternator (G1)

Display unit (N2)

Correction • Check the battery voltage.

• Check the fuse F7.

• Check that when the ignition is on, the pin 26 must have 12 V and pin 25 must be chassis earth.

• Check if the connector is connected.

• Check that when the alternator and display unit are switched on, pin 8 of X2 must have 0 V = chassis earth.

• Check that when the engine is running, on the other hand, it must have 12 V. • If the battery charges anyway (voltage approximate 14 V), the problem is probably with (N2).

Additional error codes are displayed, deal with them based on these instructions and the instructions in the fault codes list.

Error warning indicator H1 lights up

Oil pressure warning indicator H3 lights up when engine is running

Engine oil pressure switch (S55)

When the engine is stopped, the connection must have contact to chassis earth. The switch must be open when the engine is running.

• Check the connector.

• Check the oil level.

Water temperature warning indicator H4 lights up

Cooling water temperature switch (S56)

• Check the oil pressure.

• The switch must be open when the machine is cold.

• Check wiring for short-circuits.

Hydraulic oil temperature Hydraulic oil cooler warning indicator H5 lights up

• Check if the radiator body is badly soiled.

The warning indicator lights up at 85 °C (185.0 °F) oil temperature.

F32 lights up additionally at 95 °C (203.0 °F)

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Electrical systems - Warning indicators, alarms, and instruments

Problem

Possible Cause Hydraulic oil cooler fan (M2) Fuse (15) Relay (K5) Temperature sensor (S53)

Emergency stop warning Emergency stop (S2) indicator H6 lights up

Correction • Check the fan.

• Check if the connector is connected.

• Check the fuse (F15) The relay must be de-energized in operation (pin 86) and there must be contact between connections 30 and 87a.

Using diagnosis, you can check effective measured temperature. If it differs severely from real temperature, replace the sensor.

If the machine works anyway, the problem is with the wiring from (S2) to (N2).

• Otherwise, check wiring of S2 and connectors X14 and X23.

• Check the switch.

The switch (pin 1 to 3) must be open when tank is full.

Tank reserve warning indicator H7 lights up solid or never

Tank sensor (S54)

Preheating control lamp H8 never lights up

Ignition switch (S1)

Check that In ignition preheating position, pin 8 has 12 V.

Preheating coil (R1)

• Check that heating coil has 12 V.

Fuse (F14)

• Check wiring from ignition to connector X15 and display unit N2.

• Check the fuse F14.

Brake pressure control lamp H9 lights up in operation or goes out at standstill

• Check if the connector is connected.

Brake pressure sensor (S52)

The switch must be open when machine is standing still.

• Check the connector.

Supply pressure = Brake pressure Brake valve and brakes Tank display A1 doesn`t work

Tank sensor (S54)

Control lamps go out when you try to start the diesel engine

Battery

• Use diagnosis to determine whether the switch has a loose connection (see line 5.6 of process data Electrical system Check - Process data (55.000)).

Note: S52 only influences warning indicator H9.

• Check the supply pressure.

• Check the brake valve.

• Check the brakes.

• Check that the resistance between pin 2 and 3 is between 5 Ω = full and 330 Ω = empty depending on fuel level.

• Check the connector.

• Charge the battery.

Cable

• Check for rusted terminals, poor ground and loose cables.

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Electrical systems - Warning indicators, alarms, and instruments

Problem

Possible Cause Aggregates get stuck, block

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Correction • Check diesel engine, starter, water pump and flanged hydraulic pumps.

Electrical systems - Warning indicators, alarms, and instruments

Backup or reverse alarm switch - Troubleshooting Problem Reversing alarm doesn’t work

Possible Cause Display unit N2

Reversing alarm B11

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Correction • The alarm can only work if BUS is not displayed on the display unit and the machine can be driven!

• As soon as the machine drives backwards, the output (cable 312) must have + 12 V. • Check if the connector is connected.

Index Electrical systems - 55 Warning indicators, alarms, and instruments - 408 Backup or reverse alarm switch - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

Instrument cluster - Fault code index Display upon start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Instrument cluster - Overview ACE force (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Warning indicators, alarms, and instruments - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

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Electrical systems - 55 Cab controls - 512

DV23CC DV23 DV26CC DV26

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Contents Electrical systems - 55 Cab controls - 512

FUNCTIONAL DATA Armrest control panel Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Armrest control panel Check - Operating lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

DIAGNOSTIC Horn control switch Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Seat heater Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Electrical systems - Cab controls

Armrest control panel - Component identification

SS13A394

Pos. 1 2 3 4 5

Designation Parking brake S17

1

Pos. 6

Flow divider S19

7

Socket for seat heating X12 Connector for warning buzzer X55 (in box) Connector for reversing alarm X54 (in box)

8 9

Designation Connector for edge cutter operating lever X52 (in box) (Option; not available in NA) Potentiometer with neutral-position switch S3 (connector in box) Water S4 (2) (connector in box) Vibration S4 (1) (connector in box)

NOTE: Socket X12 can also be used for other purpose. All connectors ø 11.7 mm (0.46 in) to DIN72591 or ISO4165 should fit. The socket is fused to 10 A (F8).

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Electrical systems - Cab controls

Armrest control panel - Check - Operating lever Prior operation: Electrical system - Connect - Diagnosis hardware to the machine (55.000).

Operating lever errors F21, F22, F23, F24 and errors F38 and F39 indicate a defective operating lever and always cause a machine standstill. Below is a description of how to check the operating lever for proper functioning.

NOTE: Always check the wiring for short-circuits and connectors for water ingress.

1. Perform a diagnosis while the diesel engine is stopped and display the process data. Refer to Electrical system - Check - Process data (55.000).

Observe the following values: 1.1: Operating lever left (option) 1.2: Neutral switch left (option) 1.3: Operating lever right 1.4: Neutral switch right

SS12K442

1

SS12K443

2

2. Push the operating lever (1) slowly into neutral position.

Neutral position (notch) must be inside the voltage range (2). See figure 3.

3. Move the operating lever slowly out of neutral position and observe the switching point of the neutral switch.

The neutral switch must always be ON in range (3) and always OFF in range (4) (see figure 3).

4. Move the operating lever slowly back to neutral position and observe the switching point again.

5. Repeat the procedure for the other direction of travel.

SS12K444

3

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Electrical systems - Cab controls

Horn control switch - Troubleshooting Problem Horn not working

Fuse F6 Button S9

Possible Cause

Correction • Check the fuse F6.

• Check if the connector is connected.

Horn B1

• Check the button.

• Check if the connector is connected.

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Electrical systems - Cab controls

Seat heater - Troubleshooting Problem Socket X12 doesn’t work Seat heating does not work (option)

Possible Cause Fuse F8 Heating R11

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Correction • Check the fuse F8.

• Check the fuse F8.

Index Electrical systems - 55 Cab controls - 512 Armrest control panel - Check - Operating lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Armrest control panel - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Horn control switch - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Seat heater - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

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Electrical systems - 55 Electronic modules - 640

DV23CC DV23 DV26CC DV26

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Contents Electrical systems - 55 Electronic modules - 640

TECHNICAL DATA Electronic module Electrical system - General specification - Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Electronic module Component localization - Machine controller N1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Controller Area Network (CAN) data bus Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Electrical systems - Electronic modules

Electrical system - General specification - Diagnosis This machine is equipped with an electronic machine controller from Bosch Rexroth. It is model RC2-2/21 with 16 inputs and 4 outputs. Not all machine functions are routed through the controller, only a selection: • Drive control (pump forwards and backwards and the parking brake) • Vibration (partially) • Sprinkler (partially) • Hydraulic oil cooler • Reverse alarm • Seat contact warning buzzer • Various displays (error, oil temperature, brake pressure warning indicator, and error code and asphalt temperature display) The software used was specially developed for our requirements and features a drive control system optimized for rollers.

NOTE: Diagnosis can help locate an error. However, the error code displayed on the multifunction instrument is usually sufficient and only very few errors can be remedied by accessing the controller.

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Electrical systems - Electronic modules

Electronic module - Component localization - Machine controller N1 The controller N1 is located under the floor panel under the seat of the driver’s position.

The controller has the following functions: • Controls: – Drive pump – Sprinkling (Option; not available in NA) – Vibration – Reverse alarm – Warning buzzer • Various displays on the display N2.

NOTICE: The controller and the associated connector are protected against splashing, but nevertheless avoid exposing the device to a direct jet of water.

SS13A208

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1

Electrical systems - Electronic modules

Controller Area Network (CAN) data bus - Dynamic description Introduction CAN is an acronym for Controller Area Network. The bus connects controllers on a machine, and allows information to be shared between the controllers. CAN was first developed by Bosch and Intel in 1984, and has been in use in the automotive and truck industry since the late 1980‘s. Applications of CAN follow guidelines that are established in SAE J1939.

Glossary of terms Bus CAN CAN HI CAN LO Controller

Terminator

The network, e.g. the wires, connectors, and terminators between the controllers.

Controller Area Network. Generally refers to all parts of the system -the controllers, wires, and terminators.

A high priority, message carrying wire on the CAN bus.

A low priority, message carrying wire on the CAN bus.

Components that are connected by the bus and share information. May also be referred to as processors, control modules, units, or modules.

An electrical resistor or circuit placed at either end of the bus. They may be passive or active type. They may be a separate component or part of a controller. Terminators prevent a message from rebounding along the bus, clear the bus for the next message, and allow clear messages to travel the bus.

Purpose In the past, if a speed sensor‘s information was needed by a tachometer, an engine controller, and a transmission, the three devices would need to be wired to the speed sensor. The complexity of wiring can be greatly reduced through the use of a CAN bus system. A controller sends the speed sensor data onto the bus, and the other controllers on the bus can read the data. Any controller on the bus that does not care about the data will ignores the message.

A CAN bus system also offers improved diagnostics with the use of the Electronic Service Tool (EST). The controllers can detect errors, and fault codes can be displayed to the operator and technician. Onboard diagnostics may provide the ability to test and monitor circuits during operation, aiding in troubleshooting.

The advantage of a CAN bus system are: 1. A decrease in the number of wires and overall length of the wiring harness.

2. Information is received by one controller which shares the information with the other controllers on the bus.

3. Less wiring and fewer connectors improve reliability and durability.

4. Improved diagnostics with the EST.

Operation When the CAN bus is initially powered up (keyswitch on), each controller on the bus sends a message announcing its existence and looks for messages from other controllers on the bus. After this initial message, each controller sends data messages as necessary. The frequency of these messages is based on software programming, with important messages broadcast more frequently than low priority messages.

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Electrical systems - Electronic modules

RAIL13TR03931FA

1

If a controller has not sent any messages within five seconds, it will broadcast a message that announcing its existence. This is done in order to monitor each controller’s status on the bus. If a certain controller has not transmitted any messages for more than five seconds, then the other controllers on the bus will generate an alarm message indicating that a controller is offline.

NOTE: This offline status condition may vary from one machine type to another. Some machines may need to be configured to know that a specific controller is on the bus. However, this process of existence messages generally holds true.

In a CAN system, controllers are positioned near the majority of their sensors and switches. For example, the Engine Control Unit (ECU) is located in the engine compartment near the engine sensors. This results in less wiring, fewer connections, and a reduction in the number of error sources.

The voltage signal from sensors and switches are processed by a controller, which converts the signal to a data message. The data message is sent to the bus by the controller. Every controller that is connected to the bus can read and process the data message as required. Each controller knows which information it needs based on the software that is programmed into it.

The terminators absorb the voltage signals at either end of the bus. They are constantly trying to maintain of voltage of 2.5 V on the bus. Terminators prevent a signal from rebounding along the bus, clear the bus for the next signal, and allow clear messages to travel the bus.

Terminators Terminators help eliminate the reflections that can occur when a message reaches the end of the bus. These reflections can cause interference (noise) on a CAN bus, creating communication problems between the controllers.

A good way to explain how terminators work is to think about dropping a stone into a pond. After the stone hits the water, the waves travel to the edges of the pond and then rebound to the center. Terminators absorb the waves at the edges and deny the rebound of the waves to the source.

Passive terminator or active terminator 1. Passive terminators are usually 120 Ί resistors placed at either end of the bus. Passive terminators are typically used with a two wire CAN system. These resistors are connected between the CAN HI and CAN LO wires. Passive termination is popular because it is a fraction of the cost of active terminators. Passive terminators act as snubbers to kill reflections and work efficiently on systems with lower bus loading (low CAN bus traffic).

2. Active terminators are voltage regulators, and require a external voltage supply to operate. Active terminators are typically used with a four wire CAN system. Active terminators produce 2.5 V on the CAN HI and CAN LO wires to maintain the standard CAN wire voltage. This means they bring the wires to neutral. Active terminators are very efficient, and are typically used on systems with high bus loading (high traffic).

Troubleshooting The CAN system is capable of diagnosing itself and generating an alarm messages to the operator when problems are present. The vehicle may continue to function when an alarm messages appears, but the systems related to that controller may no longer function. When troubleshooting a vehicle with suspected CAN system failure, it is important to determine if the problem is related to one or more controllers or if the bus is at fault.

CAN system problems will generally fall into two categories: 48142067 15/09/2017

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Electrical systems - Electronic modules

1. Problems with individual controllers that affect certain functions, such as transmission or engine operation.

2. Problems with the bus. (The wires between the controllers.)

Some questions to answer are: 1. What functions are affected?

2. Are the affected functions related to a specific controller or several different controllers?

3. Are there any error codes or alarm messages active?

4. Are the error codes and/or alarm messages related to a specific controller or are they indicating an fault with the entire system?

If only one or two controllers are affected on the vehicle, then those controllers should be tested for faults before suspecting a CAN bus failure.

There are two general conditions that may cause an individual controller to go offline.

1. Loss of power or ground to the controller.

2. Controller related faults, such as a CAN controller failure, poor or failed CAN connector, or message errors.

Loss of power or ground The controllers are not powered through the CAN bus wires. Each controller requires a power supply and ground supply. If power or ground is lost, the controller will deactivate and will not be active on the bus. In addition, most controllers require a minimal voltage level to activate, so weak batteries, a faulty charging system, or poor connections may prevent controllers from properly activating.

Controller faults Whenever a controller transmits or receives a fault message, it keeps a record of that error. After its error history fills, the controller assumes that it is faulty, and will stop transmitting on the bus. We describe this situation as a controller that has gone “bus off,” which may cause an alarm message to be displayed. This error history is erased and reset at zero when the controller is deactivated.

There are several CAN related faults that may cause a controller to go offline: 1. External problems like bad or open connections to the CAN HI wires and CAN LO wires as a result of damaged wiring. Inspect the wiring for damage, and use a multimeter to check for continuity to the wires.

2. Internal problems like a failure of the controller itself. If the controller is activating but never communicates on the bus, the controller may have failed. If the controller is activating and is initially online but goes offline after a short period of operation, it may be in a bus off state.

Faulty messages may result from: 1. Failed terminators (signal reflection occurring) on the CAN bus. Test the terminators for proper operation.

2. Bad connections (e.g. loose pins, corroded terminals, damaged wires) between the controller and the bus.

3. A problem with the controller.

If several controllers are offline or the vehicle will not start, there may be a problem with the actual CAN bus. The wires may be shorted to 12 V, shorted to ground, open, or shorted together. Any of these problems can affect the entire CAN bus.

Testing the CAN bus There are several things to consider when testing CAN systems. The primary concern should be to confirm the integrity of the CAN bus circuit, after which you should check for shorts to battery voltage or to chassis ground.

You can easily test the CAN bus (CAN HI and CAN LO) for open circuits by conducting a circuit continuity check at the vehicle’s diagnostic connector. However, for vehicles that use active terminators, it is necessary to unplug those terminators, and replace them with jumper wires between the CAN HI wires and CAN LO wires.

For our machine, we deactivate all systems and use a multimeter (1) to check the resistance between pins C and D of our vehicle’s diagnostic connector (2).

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Electrical systems - Electronic modules

NOTE: The CAN circuit that is being tested must be connected to the diagnostic connector.

RAIL13TR03932FA

2

The resistance across the CAN circuit between CAN HI (3) and CAN LO (4) should be approximately 54 – 66 Ω. A reading of 54 – 66 Ω indicates that the passive terminators are good and confirms the integrity of the CAN bus circuit.

A reading of 70 – 150 Ω generally indicates that either a passive terminator has failed or there is an open circuit in either the CAN HI wires or CAN LO wires. You must perform additional testing to isolate the source of the fault.

A reading of infinite resistance indicate that either both passive terminators have failed or there is an open circuit in both CAN HI wires and CAN LO wires.

A reading of 53 Ω or less indicates poor connections in the circuit.

A reading of very low resistance indicates that the CAN HI wires and CAN LO wires are shorted together. Additional testing must be completed to determine the location of the short.

Testing the terminators If a passive terminator is suspected as a source of a CAN bus problem, disconnect the passive terminator from the CAN bus and test the resistance of passive terminators with a multimeter. Passive terminators should have a resistance of approximately 120 Ω.

NOTE: Some terminators may be an internal part of a controller. Disconnect the controller from the harness before testing.

Testing the CAN bus voltage A CAN circuit can be tested by testing the voltage of the CAN HI wires and CAN LO wires while the system is activated.

This test may provide some indication if the CAN circuit is shorted to high voltage or to ground, but is not conclusive of CAN system operation. If a fault is suspected, you must complete additional testing to locate the type and source of the fault.

Use a multimeter to check the voltage between either the CAN HI wires or CAN LO wire and chassis ground.

1. The CAN HI circuit should read approximately 2.5 – 3.5 V. 2. The CAN LO circuit should read approximately 1.5 – 2.5 V.

Testing the CAN bus for shorts to battery voltage If there is a short from a 12 V source to CAN HI or CAN LO, the controllers cannot send information on the CAN system.

With the keyswitch on, use a multimeter to check the voltage from the circuit to ground. This needs to be carried out for both the CAN HI and CAN LO wires. If data line voltage is at battery voltage, data can no longer be transmitted. If such an error is found on a data line, localize the error by opening the circuit at intermediate connectors and repeating this test.

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Testing the CAN bus for shorts between the wires If there is a short between the CAN HI wires and CAN LO wires, the controllers cannot send information on the CAN bus.

Turn the keyswitch off. Disconnect the terminators from the CAN HI wires and CAN LO wires, so the wires are open.

Use a multimeter to check for continuity between the CAN HI wires and CAN LO wires. If there is continuity, the two wires are shorted together. If such an error is found, localize the error by opening the circuit at intermediate connectors and repeating this test.

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Index Electrical systems - 55 Electronic modules - 640 Controller Area Network (CAN) data bus - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Electrical system - General specification - Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Electronic module - Component localization - Machine controller N1 . . . . . . . . . . . . . . . . . . . . . . . . . .

4

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Electrical systems - 55 External lighting - 404

DV23CC DV23 DV26CC DV26

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Contents Electrical systems - 55 External lighting - 404

SERVICE Brake light Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

DIAGNOSTIC External lighting Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Electrical systems - External lighting

Brake light - Program NOTE: Both the warning buzzer and the brake lights are optional accessories.

With the default setting, the warning buzzer will be activated as soon as a seat contact delay of more than 1 s is selected.

If you want the brake lights to be turned on instead of the warning buzzer, follow the steps 1 – 4.

Activating and deactivating the brake lights 1. Remove the cover (1) on the steering column.

SS12K220

1

SS13A774

2

2. Turn the ignition off (0) and then back on (I).

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Electrical systems - External lighting

3. Now jumper the two contacts of X8 with the connector.

NOTE: You can also use a piece of wire as a makeshift.

SS13A775

3

SS13A776

4

4. You can now switch between the warning buzzer and the brake lights by holding down the vibration button (1) for at least 10 s.

After switching, the display will either show “B13” for the warning buzzer or “E24” for the brake lights.

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Electrical systems - External lighting

External lighting - Troubleshooting Problem Parking light doesn’t work Bulb Relay K14

Possible Cause

• The relay must switch as soon as ignition is switched on.

Check if the connector is connected.

• • Check fuses F2 and F3.

• Check the bulb.

• Check the relay K14.

Switch S10 Fuses F2 and F3 Dipped light doesn’t work Bulb Relay K14

Work light doesn’t work

Indicator and hazard flasher doesn’t work

Correction • Check the bulb.

• Check the relay K14.

Switch S10 Fuse F4 Bulb Fuse F5 Switch S11 Bulb

• The relay must switch as soon as ignition is switched on.

• Check if the connector is connected.

• Check the fuse F4.

• Check the bulb.

• Check the fuse F5.

• Check if the connector is connected.

• Check the bulb.

Fuse F1 Fuse F7 Switch S12 Indicator relay K11

• • • •

Check the fuse F1.

Check the fuse F7.

Check if the connector is connected.

Check that connection + (cable 414) has 12 V when ignition is on, if S12 is pressed when ignition is off, too.

• Check if the connector is connected.

Switch S13

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Index Electrical systems - 55 External lighting - 404 Brake light - Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

External lighting - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

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Electrical systems - 55 FAULT CODES - DTC

DV23CC DV23 DV26CC DV26

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Contents Electrical systems - 55 FAULT CODES - DTC

DIAGNOSTIC -11 - Seat contact open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -12 - Operating lever is deflected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -13 - Both operating levers are deflected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -14 - Parking brake is activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 -15 - Engine is not running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 BUS - No data from CAN bus to the display unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 F21 - Error operating lever right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 F22 - Operating lever right neutral signal does not match operating lever signal . . . . . . . . . . . . . . . . . . . 16 F23 - Error operating lever left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 F24 - Operating lever left neutral signal does not match operating lever signal . . . . . . . . . . . . . . . . . . . . . 20 F25 - Sprinkler potentiometer error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 F26 - Resistance outside permissible range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 F27 - Error proportional magent pump forwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 F28 - Error proportional magnet pump backwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 F29 - Error switching magnet vibration relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 F30 - Error switching magnet brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 F31 - Battery voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 F32 - Oil temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 F33 - Internal power supply outside permissible range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 F33 - Internal power supply outside permissible range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 F35 - Restricted ability of pump to be switched off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 F36 - Pump magnet forwards failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 F37 - Pump magnet backwards failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 F38 - Wrong direction of travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 F39 - Flow with operating lever in neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 F40 - Program sequence failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 F41 - Starting condition failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 F42 - Asphalt temperature sensor failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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Electrical systems - FAULT CODES

-11 - Seat contact open Context: Fault code –11 shows on the display unit above the hour counter and prevents start-up of the machine.

Cause: 1. Operator is not sitting on the seat.

2. Electrical component failure.

Possible failure modes: 1. Open circuit in the seat switch wiring.

2. Faulty connector (X50).

3. Faulty seat contact switch (S51).

4. Faulty machine controller (N1).

Solution: 1. Verify that the fault code is active.

Sit on the seat and check if the fault code disappears from the display unit.

A. If fault code is cleared, proceed to start the engine.

B. If fault code is not cleared, proceed to step 2.

2. Check connector (X50) and harness.

Remove the floor panel.

Inspect connector (X50) and the harness. They should be secure, tight, free of corrosion, abrasion and damage.

A. The connector is secure and the harness is free of damage. Proceed to step 3.

B. The connector is not secure or the harness is damaged. Replace the connector or harness as required. Return to step 1 to confirm elimination of the fault.

3. Test connector (X50).

Disconnect connector (X50).

Remove wires 366 (pin 9) and 371 (pin 10) from the connector.

Sit in the operator’s seat and turn the ignition switch ON. Fault codes –11 (Seat contact open) and F21 (Error operating lever right) will be displayed in rotation.

Use a jumper wire with alligator clips to connect wire 366 to wire 371 and check the display.

A. Fault code –11 is cleared: the problem lies either with seat contact switch (S51) or the wiring between seat contact switch (S51) and connector (X50). Repair as required. Return to step 1 to confirm elimination of the fault.

B. Fault code –11 is still active: the problem lies either with the electronic machine controller (N1) or the wiring between connector (X50) and electronic machine controller (N1). Proceed to step 4.

4. Check electronic machine controller (N1) and wiring harness.

Remove the seat assembly in order to access the electronic machine controller (N1). Refer to section Platform Remove (90.110) for procedure.

Unplug the harness coming from connector (X50).

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Electrical systems - FAULT CODES

Disconnect wires 366 (pin 36) and 371 (pin 48) from that plug.

Measure the resistance between the end of wire 366 (pin 36) and the end of wire 371 (pin 48). The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.

A. The resistance is less than 10 Ω. Replace the electronic machine controller (N1). Return to step 1 to confirm elimination of the fault.

B. The resistance is greater than 20,000 Ω. There is a short circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault.

Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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-12 - Operating lever is deflected Context: Fault code –12 shows on the display unit above the hour counter and prevents start-up of the machine.

Cause: 1. Operating lever is not in the neutral position.

2. Electrical component failure.

Possible failure modes: 1. Faulty connector (X50).

2. Faulty operating lever sensor, right (S3).

3. Faulty operating lever, right 4. Open circuit in the wiring harness.

5. Faulty machine controller (N1).

Solution: 1. Verify that the fault code is active.

Move the right operating lever slightly forward and backward, then back into the neutral position. Check if the fault code disappears from the display unit.

A. If fault code is cleared, proceed to start the engine.

B. If fault code is not cleared, proceed to step 2.

2. Check connector (X50) and harness.

Remove the floor panel.

Inspect connector (X50) and the harness. They should be secure, tight, free of corrosion, abrasion and damage.

A. The connector is secure and the harness is free of damage. Proceed to step 3.

B. The connector is not secure or the harness is damaged. Replace the connector or harness as required. Return to step 1 to confirm elimination of the fault.

3. Check connector in armrest control panel.

Refer to section Armrest control panel - Component identification (55.512).

Remove the side panel of the armrest control panel to access the connectors under the operating lever.

Inspect the 6–pin connector with wires 901, 903, 911, 914 and 915 and the harness. They should be secure, tight, free of corrosion, abrasion and damage.

A. The connector is secure and the harness is free of damage. Proceed to step 4.

B. The connector is not secure or the harness is damaged. Replace the connector or harness as required. Return to step 1 to confirm elimination of the fault.

4. Check the right operating lever and potentiometer switch (S3).

Release the rubber boot at the bottom of he right operating lever and remove the 4 screws. Refer to section Operator platform less cab - Replace Operating lever (90.110).

Remove the operating lever assembly to gain access to the potentiometer switch (S3) at the bottom of the operating lever.

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Inspect the wires connected to the potentiometer switch (S3) and he harness. They should be secure, tight, free of corrosion, abrasion and damage.

Make sure that the bolt that is in contact with the potentiometer switch (S3) is securely attached to the lever.

A. The wires are securely connected to he potentiometer switch (S3), the harness is free of damage and the bolt is securely attached to the lever. Proceed to step 5.

B. The wires are not securely connected to he potentiometer switch (S3), the harness is damaged or the bolt is loose. Repair or replace components as required. Return to step 1 to confirm elimination of the fault.

5. Replace the right operating lever.

A. The fault code is still recorded. Proceed to step 6.

B. The fault code is no longer recorded. Proceed to start the engine.

6. Check electronic machine controller (N1) and wiring harness.

Remove the seat assembly in order to access the electronic machine controller (N1). Refer to section Platform Remove (90.110) for procedure.

Unplug the harness coming from connector (X50).

Disconnect wires 366 (pin 36) and 369 (pin 11) from that plug.

Measure the resistance between the end of wire 366 (pin 36) and the end of wire 369 (pin 11). The resistance should be less than 10 Ί. Wiggle the harness during measurement to reveal an intermittent condition.

A. The resistance is less than 10 Ί. Replace the electronic machine controller (N1). Return to step 1 to confirm elimination of the fault.

B. The resistance is greater than 20,000 Ί. There is a short circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault.

Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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-13 - Both operating levers are deflected Context: Fault code –13 shows on the display unit above the hour counter and prevents start-up of the machine.

Cause: 1. One or both operating levers are not in the neutral position.

2. Electrical component failure.

Possible failure modes: 1. Faulty connector (X50).

2. Faulty operating lever sensor, right (S3).

3. Faulty operating lever sensor, left (S15).

4. Open circuit in the wiring harness.

5. Faulty machine controller (N1).

Solution: 1. Verify that the fault code is active.

Move the right operating lever slightly forward and backward, then back into the neutral position. Check if the fault code disappears from the display unit.

Move the left operating lever slightly forward and backward, then back into the neutral position. Check if the fault code disappears from the display unit.

A. If fault code is cleared, proceed to start the engine.

B. If fault code is not cleared, proceed to step 2.

2. Check connector (X50) and harness.

Remove the floor panel.

Inspect connector (X50) and the harness. They should be secure, tight, free of corrosion, abrasion and damage.

A. The connector is secure and the harness is free of damage. Proceed to step 3.

B. The connector is not secure or the harness is damaged. Replace the connector or harness as required. Return to step 1 to confirm elimination of the fault.

3. Check connector in right armrest control panel.

Refer to section Armrest control panel - Component identification (55.512).

Remove the side panel of the right armrest control panel to access the connectors under the right operating lever.

Inspect the 6–pin connector with wires 901, 903, 911, 914 and 915 and the harness. They should be secure, tight, free of corrosion, abrasion and damage.

A. The connector is secure and the harness is free of damage. Proceed to step 4.

B. The connector is not secure or the harness is damaged. Replace the connector or harness as required. Return to step 1 to confirm elimination of the fault.

4. Check the right operating lever and potentiometer switch (S3).

Release the rubber boot at the bottom of he right operating lever and remove the 4 screws. Refer to section Operator platform less cab - Replace Operating lever (90.110).

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Remove the operating lever assembly to gain access to the potentiometer switch (S3) at the bottom of the operating lever.

Inspect the wires connected to the potentiometer switch (S3) and he harness. They should be secure, tight, free of corrosion, abrasion and damage.

Make sure that the bolt that is in contact with the potentiometer switch (S3) is securely attached to the lever.

A. The wires are securely connected to he potentiometer switch (S3), the harness is free of damage and the bolt is securely attached to the lever. Proceed to step 5.

B. The wires are not securely connected to he potentiometer switch (S3), the harness is damaged or the bolt is loose. Repair or replace components as required. Return to step 1 to confirm elimination of the fault.

5. Check connector in left armrest control panel.

Refer to section Armrest control panel - Component identification (55.512).

Remove the side panel of the left armrest control panel to access the connectors under the operating lever.

Inspect the 6–pin connector with wires 902, 904, 913, 919 and 920 and the harness. They should be secure, tight, free of corrosion, abrasion and damage.

A. The connector is secure and the harness is free of damage. Proceed to step 6.

B. The connector is not secure or the harness is damaged. Replace the connector or harness as required. Return to step 1 to confirm elimination of the fault.

6. Check the left operating lever and potentiometer switch (S15).

Release the rubber boot at the bottom of he left operating lever and remove the 4 screws. Refer to section Operator platform less cab - Replace Operating lever (90.110).

Remove the operating lever assembly to gain access to the potentiometer switch (S15) at the bottom of the operating lever.

Inspect the wires connected to the potentiometer switch (S15) and he harness. They should be secure, tight, free of corrosion, abrasion and damage.

Make sure that the bolt that is in contact with the potentiometer switch (S15) is securely attached to the lever.

A. The wires are securely connected to he potentiometer switch (S15), the harness is free of damage and the bolt is securely attached to the lever. Proceed to step 7.

B. The wires are not securely connected to he potentiometer switch (S15), the harness is damaged or the bolt is loose. Repair or replace components as required. Return to step 1 to confirm elimination of the fault.

7. Check electronic machine controller (N1) and wiring harness.

Remove the seat assembly in order to access the electronic machine controller (N1). Refer to section Platform Remove (90.110) for procedure.

Unplug the harness coming from connector (X50).

Disconnect wires 366 (pin 36) and 369 (pin 11) from that plug.

Measure the resistance between the end of wire 366 (pin 36) and the end of wire 369 (pin 11). The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.

Disconnect wires 366 (pin 36) and 370 (pin 34) from that plug.

Measure the resistance between the end of wire 366 (pin 36) and the end of wire 370 (pin 34). The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.

A. The resistance is less than 10 Ω. Replace the electronic machine controller (N1). Return to step 1 to confirm elimination of the fault.

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B. The resistance is greater than 20,000 Ί. There is a short circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault.

Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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-14 - Parking brake is activated Context: Fault code –14 shows on the display unit above the hour counter and prevents start-up of the machine.

Cause: 1. Parking brake is not released.

2. Electrical component failure.

Possible failure modes: 1. Faulty parking brake switch (S17).

2. Faulty connector (X1).

3. Faulty locking brake valve (Y2).

4. Open circuit in the wiring harness.

5. Faulty machine controller (N1).

Solution: 1. Verify that the fault code is active.

Push the parking brake switch (S17). Check if the fault code disappears from the display unit.

A. If fault code is cleared, proceed to start the engine.

B. If fault code is not cleared, proceed to step 2.

2. Check the parking brake switch (S17) and harness.

Refer to section Armrest control panel - Component identification (55.512).

Remove the side panel of the armrest control panel to access the components under the operating lever.

Inspect the parking brake switch (S17) and the harness. They should be secure, tight, free of corrosion, abrasion and damage.

A. The switch and the harness are free of damage. Proceed to step 3.

B. The switch or the harness is damaged. Replace the switch or harness as required. Return to step 1 to confirm elimination of the fault.

3. Check connector (X1).

Remove panel from steering column. Refer to section Fuse and relay box - Component localization - Steering column (55.100).

Inspect connector (X1) and the harness. They should be secure, tight, free of corrosion, abrasion and damage.

A. The connector is secure and the harness is free of damage. Proceed to step 4.

B. The connector is not secure or the harness is damaged. Replace the connector or harness as required. Return to step 1 to confirm elimination of the fault.

4. Check locking brake valve (Y2) Inspect locking brake valve (Y2) and the harness. They should be secure, tight, free of corrosion, abrasion and damage.

A. The valve and the harness are free of damage. Proceed to step 5.

B. The valve or the harness is damaged. Replace the valve or harness as required. Return to step 1 to confirm elimination of the fault.

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5. Check electronic machine controller (N1) and wiring harness.

Remove the seat assembly in order to access the electronic machine controller (N1). Refer to section Platform Remove (90.110) for procedure.

Inspect electronic machine controller (N1) and wiring harness. They should be secure, tight, free of corrosion, abrasion and damage.

A. The wiring harness has damage. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault.

B. The wiring harness is not damaged. Replace the electronic machine controller (N1). Return to step 1 to confirm elimination of the fault.

Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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-15 - Engine is not running Context: Fault code –15 shows on the display unit above the hour counter and prevents start-up of the machine.

Cause: 1. Electrical component failure.

Possible failure modes: 1. Connector (X3) 2. Fuse (F22) 3. Alternator (G1) Solution: 1. Check connector (X3).

Remove panel from steering column. Refer to section Fuse and relay box - Component localization - Steering column (55.100).

Inspect connector (X3) and the harness. They should be secure, tight, free of corrosion, abrasion and damage.

A. The connector is secure and the harness is free of damage. Proceed to step 2.

B. The connector is not secure or the harness is damaged. Replace the connector or harness as required. Confirm that fault code is no longer recorded.

2. Check if pin 6 in connector (X3) has an alternating current signal.

A. Pin 6 in connector (X3) has an alternating current signal. Go to step 3.

B. Pin 6 in connector (X3) does not have an alternating current signal. Replace the connector. Confirm that fault code is no longer recorded.

3. Check fuse (F22).

Inspect fuse (F22) in engine compartment. Refer to section Fuse and relay box - Component localization Engine (55.100) A. The fuse is not defective. Proceed to step 4.

B. The fuse is defective. Replace the fuse. Confirm that fault code is no longer recorded.

4. Check alternator (G1).

Inspect all connections to the alternator (G1). They should be secure, tight, free of corrosion, abrasion and damage.

A. The connections are not secure or the harness is damaged. Replace the connections or harness as required.

Confirm that fault code is no longer recorded.

B. The connections are secure and the harness is free of damage Replace the alternator (G1). Confirm that fault code is no longer recorded.

Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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BUS - No data from CAN bus to the display unit Context: Fault code BUS shows on the display unit above the hour counter and prevents start-up of the machine.

Cause: 1. The display unit (N2) is not receiving any data from the controller (N1).

Possible failure modes: 1. Faulty fuse (F9) 2. Faulty connector (X7) 3. Damaged wiring harness.

4. Faulty controller (N1) Solution: 1. Check fuse (F9).

Remove panel from steering column. Refer to section Fuse and relay box - Component localization - Steering column (55.100).

Inspect fuse (F9) in steering column.

A. The fuse is not defective. Proceed to step 2.

B. The fuse is defective. Replace the fuse. Confirm that fault code is no longer recorded.

2. Check the wiring from the display unit (N2) to the connector (X7).

Wires and connections should be secure, tight, free of corrosion, abrasion and damage.

A. The connections are secure and the harness is free of damage. Proceed to step 3.

B. The connections are not secure or the harness is damaged. Repair or replace the connections or harness as required. Confirm that fault code is no longer recorded.

3. Check controller (N1) and wiring harness.

Remove the seat assembly in order to access the electronic machine controller (N1). Refer to section Platform Remove (90.110) for procedure.

Inspect the connections of wires 342 (pin 39) and 344 (pin 40) at controller (N1).

Inspect the wiring from the controller (N1) to the connector (X7).

A. The connections are not secure or the harness is damaged. Repair or replace the connections or harness as required. Confirm that fault code is no longer recorded.

B. The connections are secure and the harness is free of damage. Replace the controller (N1). Confirm that fault code is no longer recorded.

Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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F21 - Error operating lever right Context: Fault code F21 shows on the display unit above the hour counter and prevents driving of the machine. Limited driving might be possible with the left operating lever, if equipped.

Cause: 1. Electrical component failure.

Possible failure modes: 1. Faulty connector (X50).

2. Faulty operating lever sensor, right (S3).

3. Faulty operating lever, right 4. Open circuit in the wiring harness.

5. Faulty machine controller (N1).

Solution: 1. Check connector (X50) and harness.

Remove the floor panel.

Inspect connector (X50) and the harness. They should be secure, tight, free of corrosion, abrasion and damage.

A. The connector is secure and the harness is free of damage. Proceed to step 2.

B. The connector is not secure or the harness is damaged. Replace the connector or harness as required. Confirm that fault code is no longer recorded.

2. Check connector in armrest control panel.

Refer to section Armrest control panel - Component identification (55.512).

Remove the side panel of the armrest control panel to access the connectors under the operating lever.

Inspect the 6–pin connector with wires 901, 903, 911, 914 and 915 and the harness. They should be dry, secure, tight, free of corrosion, abrasion and damage.

A. The connector is secure and the harness is free of damage. Proceed to step 3.

B. The connector is not secure or the harness is damaged. Replace the connector or harness as required. Confirm that fault code is no longer recorded.

3. Check the right operating lever and potentiometer switch (S3).

Release the rubber boot at the bottom of he right operating lever and remove the 4 screws. Refer to section Operator platform less cab - Replace Operating lever (90.110).

Remove the operating lever assembly to gain access to the potentiometer switch (S3) at the bottom of the operating lever.

Inspect the wires connected to the potentiometer switch (S3) and he harness. They should be secure, tight, free of corrosion, abrasion and damage.

Make sure that the bolt that is in contact with the potentiometer switch (S3) is securely attached to the lever.

A. The wires are securely connected to he potentiometer switch (S3), the harness is free of damage and the bolt is securely attached to the lever. Proceed to step 4.

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B. The wires are not securely connected to he potentiometer switch (S3), the harness is damaged or the bolt is loose. Repair or replace components as required. Confirm that fault code is no longer recorded.

4. Replace the right operating lever.

A. The fault code is still recorded. Proceed to step 5.

B. The fault code is no longer recorded. Proceed to start the engine.

5. Check electronic machine controller (N1) and wiring harness.

Remove the seat assembly in order to access the electronic machine controller (N1). Refer to section Platform Remove (90.110) for procedure.

Unplug the harness coming from connector (X50).

Disconnect wires 366 (pin 36) and 369 (pin 11) from that plug.

Measure the resistance between the end of wire 366 (pin 36) and the end of wire 369 (pin 11). The resistance should be less than 10 Ί. Wiggle the harness during measurement to reveal an intermittent condition.

A. The resistance is less than 10 Ί. Replace the electronic machine controller (N1). Return to step 1 to confirm elimination of the fault.

B. The resistance is greater than 20,000 Ί. There is a short circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault.

Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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F22 - Operating lever right neutral signal does not match operating lever signal Context: Fault code F22 shows on the display unit above the hour counter and prevents driving of the machine. Limited driving might be possible with the left operating lever, if equipped.

Cause: 1. Electrical component failure.

Possible failure modes: 1. Faulty connector (X50).

2. Faulty operating lever sensor, right (S3).

3. Faulty operating lever, right 4. Open circuit in the wiring harness.

5. Faulty machine controller (N1).

Solution: 1. Check connector (X50) and harness.

Remove the floor panel.

Inspect connector (X50) and the harness. They should be secure, tight, free of corrosion, abrasion and damage.

A. The connector is secure and the harness is free of damage. Proceed to step 2.

B. The connector is not secure or the harness is damaged. Replace the connector or harness as required. Confirm that fault code is no longer recorded.

2. Check connector in armrest control panel.

Refer to section Armrest control panel - Component identification (55.512).

Remove the side panel of the armrest control panel to access the connectors under the operating lever.

Inspect the 6–pin connector with wires 901, 903, 911, 914 and 915 and the harness. They should be dry, secure, tight, free of corrosion, abrasion and damage.

A. The connector is secure and the harness is free of damage. Proceed to step 3.

B. The connector is not secure or the harness is damaged. Replace the connector or harness as required. Confirm that fault code is no longer recorded.

3. Check the right operating lever and potentiometer switch (S3).

Release the rubber boot at the bottom of he right operating lever and remove the 4 screws. Refer to section Operator platform less cab - Replace Operating lever (90.110).

Remove the operating lever assembly to gain access to the potentiometer switch (S3) at the bottom of the operating lever.

Inspect the wires connected to the potentiometer switch (S3) and he harness. They should be secure, tight, free of corrosion, abrasion and damage.

Make sure that the bolt that is in contact with the potentiometer switch (S3) is securely attached to the lever.

A. The wires are securely connected to he potentiometer switch (S3), the harness is free of damage and the bolt is securely attached to the lever. Proceed to step 4.

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B. The wires are not securely connected to he potentiometer switch (S3), the harness is damaged or the bolt is loose. Repair or replace components as required. Confirm that fault code is no longer recorded.

4. Replace the right operating lever.

A. The fault code is still recorded. Proceed to step 5.

B. The fault code is no longer recorded. Proceed to start the engine.

5. Check electronic machine controller (N1) and wiring harness.

Remove the seat assembly in order to access the electronic machine controller (N1). Refer to section Platform Remove (90.110) for procedure.

Unplug the harness coming from connector (X50).

Disconnect wires 366 (pin 36) and 369 (pin 11) from that plug.

Measure the resistance between the end of wire 366 (pin 36) and the end of wire 369 (pin 11). The resistance should be less than 10 Ί. Wiggle the harness during measurement to reveal an intermittent condition.

A. The resistance is less than 10 Ί. Replace the electronic machine controller (N1). Return to step 1 to confirm elimination of the fault.

B. The resistance is greater than 20,000 Ί. There is a short circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault.

Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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F23 - Error operating lever left Context: Fault code F23 shows on the display unit above the hour counter and prevents driving of the machine. Limited driving might be possible with the right operating lever.

Cause: 1. Electrical component failure.

Possible failure modes: 1. Faulty connector (X50).

2. Faulty operating lever sensor, left (S15).

3. Faulty operating lever, left 4. Open circuit in the wiring harness.

5. Faulty machine controller (N1).

Solution: 1. Check connector (X50) and harness.

Remove the floor panel.

Inspect connector (X50) and the harness. They should be secure, tight, free of corrosion, abrasion and damage.

A. The connector is secure and the harness is free of damage. Proceed to step 2.

B. The connector is not secure or the harness is damaged. Replace the connector or harness as required. Confirm that fault code is no longer recorded.

2. Check connector in armrest control panel.

Refer to section Armrest control panel - Component identification (55.512).

Remove the side panel of the armrest control panel to access the connectors under the operating lever.

Inspect the 6–pin connector with wires 901, 903, 911, 914 and 915 and the harness. They should be dry, secure, tight, free of corrosion, abrasion and damage.

A. The connector is secure and the harness is free of damage. Proceed to step 3.

B. The connector is not secure or the harness is damaged. Replace the connector or harness as required. Confirm that fault code is no longer recorded.

3. Check the left operating lever and potentiometer switch (S15).

Release the rubber boot at the bottom of he left operating lever and remove the 4 screws. Refer to section Operator platform less cab - Replace Operating lever (90.110).

Remove the operating lever assembly to gain access to the potentiometer switch (S15) at the bottom of the operating lever.

Inspect the wires connected to the potentiometer switch (S15) and he harness. They should be secure, tight, free of corrosion, abrasion and damage.

Make sure that the bolt that is in contact with the potentiometer switch (S15) is securely attached to the lever.

A. The wires are securely connected to he potentiometer switch (S15), the harness is free of damage and the bolt is securely attached to the lever. Proceed to step 4.

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B. The wires are not securely connected to he potentiometer switch (S15), the harness is damaged or the bolt is loose. Repair or replace components as required. Confirm that fault code is no longer recorded.

4. Replace the left operating lever.

A. The fault code is still recorded. Proceed to step 5.

B. The fault code is no longer recorded. Proceed to start the engine.

5. Check electronic machine controller (N1) and wiring harness.

Remove the seat assembly in order to access the electronic machine controller (N1). Refer to section Platform Remove (90.110) for procedure.

Unplug the harness coming from connector (X50).

Disconnect wires 366 (pin 36) and 370 (pin 34) from that plug.

Measure the resistance between the end of wire 366 (pin 36) and the end of wire 370 (pin 34). The resistance should be less than 10 Ί. Wiggle the harness during measurement to reveal an intermittent condition.

A. The resistance is less than 10 Ί. Replace the electronic machine controller (N1). Return to step 1 to confirm elimination of the fault.

B. The resistance is greater than 20,000 Ί. There is a short circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault.

Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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F24 - Operating lever left neutral signal does not match operating lever signal Context: Fault code F23 shows on the display unit above the hour counter and prevents driving of the machine. Limited driving might be possible with the right operating lever.

Cause: 1. Electrical component failure.

Possible failure modes: 1. Faulty connector (X50).

2. Faulty operating lever sensor, left (S15).

3. Faulty operating lever, left 4. Open circuit in the wiring harness.

5. Faulty machine controller (N1).

Solution: 1. Check connector (X50) and harness.

Remove the floor panel.

Inspect connector (X50) and the harness. They should be secure, tight, free of corrosion, abrasion and damage.

A. The connector is secure and the harness is free of damage. Proceed to step 2.

B. The connector is not secure or the harness is damaged. Replace the connector or harness as required. Confirm that fault code is no longer recorded.

2. Check connector in armrest control panel.

Refer to section Armrest control panel - Component identification (55.512).

Remove the side panel of the armrest control panel to access the connectors under the operating lever.

Inspect the 6–pin connector with wires 901, 903, 911, 914 and 915 and the harness. They should be dry, secure, tight, free of corrosion, abrasion and damage.

A. The connector is secure and the harness is free of damage. Proceed to step 3.

B. The connector is not secure or the harness is damaged. Replace the connector or harness as required. Confirm that fault code is no longer recorded.

3. Check the left operating lever and potentiometer switch (S15).

Release the rubber boot at the bottom of he left operating lever and remove the 4 screws. Refer to section Operator platform less cab - Replace Operating lever (90.110).

Remove the operating lever assembly to gain access to the potentiometer switch (S15) at the bottom of the operating lever.

Inspect the wires connected to the potentiometer switch (S15) and he harness. They should be secure, tight, free of corrosion, abrasion and damage.

Make sure that the bolt that is in contact with the potentiometer switch (S15) is securely attached to the lever.

A. The wires are securely connected to he potentiometer switch (S15), the harness is free of damage and the bolt is securely attached to the lever. Proceed to step 4.

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B. The wires are not securely connected to he potentiometer switch (S15), the harness is damaged or the bolt is loose. Repair or replace components as required. Confirm that fault code is no longer recorded.

4. Replace the left operating lever.

A. The fault code is still recorded. Proceed to step 5.

B. The fault code is no longer recorded. Proceed to start the engine.

5. Check electronic machine controller (N1) and wiring harness.

Remove the seat assembly in order to access the electronic machine controller (N1). Refer to section Platform Remove (90.110) for procedure.

Unplug the harness coming from connector (X50).

Disconnect wires 366 (pin 36) and 370 (pin 34) from that plug.

Measure the resistance between the end of wire 366 (pin 36) and the end of wire 370 (pin 34). The resistance should be less than 10 Ί. Wiggle the harness during measurement to reveal an intermittent condition.

A. The resistance is less than 10 Ί. Replace the electronic machine controller (N1). Return to step 1 to confirm elimination of the fault.

B. The resistance is greater than 20,000 Ί. There is a short circuit in the wiring. Repair or replace the harness as required. Return to step 1 to confirm elimination of fault.

Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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F25 - Sprinkler potentiometer error Context: Fault code F25 shows on the display unit above the hour counter. The interval sprinkler function is not working.

Cause: 1. Electrical component failure.

Possible failure modes: 1. Faulty sprinkler potentiometer (S5).

2. Damaged wiring harness.

3. Faulty controller (N1).

Solution: 1. Check the sprinkler potentiometer (S5).

Inspect wire numbers 377, 378 on the left and right and 379 in the middle. They should be secure, free of corrosion, abrasion and damage.

A. Wires are securely connected and are free of damage. Proceed to step 2.

B. Wires are loose or damaged. Repair or replace as required. Confirm that fault code is no longer recorded.

2. Check voltage at sprinkler potentiometer (S5).

The potentiometer is supplied with +5 V and must deliver a signal between 0.5 V and 4.5 V. A. Measured voltage meets specifications. Proceed to step 3.

B. Measured voltage does not meet specifications. Replace the sprinkler potentiometer (S5). Confirm that fault code is no longer recorded.

3. Check controller (N1) and wiring harness.

Remove the seat assembly in order to access the electronic machine controller (N1). Refer to section Platform Remove (90.110) for procedure.

Inspect the connections of wires 377 (pin 47), 378 (pin 49) and 379 (pin 37) at controller (N1).

Inspect the wiring harness from the controller (N1) to the sprinkler potentiometer (S5) A. The connections are not secure or the harness is damaged. Repair or replace the connections or harness as required. Confirm that fault code is no longer recorded.

B. The connections are secure and the harness is free of damage. Replace the controller (N1). Confirm that fault code is no longer recorded.

Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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F26 - Resistance outside permissible range Context: Fault code F26 shows on the display unit above the hour counter. The temperature control is not working.

Cause: 1. Electrical component failure.

Possible failure modes: 1. Faulty connector (X3).

2. Damaged wiring harness.

3. Faulty oil temperature sensor (S53).

4. Faulty controller (N1).

Solution: 1. Check connector (X3).

Remove panel from steering column. Refer to section Fuse and relay box - Component localization - Steering column (55.100).

Inspect connector (X3), in particular wires 126 (pin 8) and 127 (pin 9). They should be secure, tight, free of corrosion, abrasion and damage.

A. The connector is secure and the wires at the connector are free of damage. Proceed to step 2.

B. The connector is not secure or the wires are loose or damaged. Repair or replace the connector or wires as required. Confirm that fault code is no longer recorded.

2. Check wiring harness from connector (X3) to oil temperature sensor (S53).

Inspect the harness. Wires should be free of corrosion, abrasion and damage.

A. The harness is free of damage. Proceed to step 3.

B. The harness is damaged. Replace or replace the harness as required. Confirm that fault code is no longer recorded.

3. Check connections at oil temperature sensor (S53).

A. Wires are securely connected and are free of damage. Proceed to step 4.

B. Wires are loose or damaged. Repair or replace as required. Confirm that fault code is no longer recorded.

4. Replace oil temperature sensor (S53).

A. Fault code is still recorded. Proceed to step 5.

B. Confirm that fault code is no longer recorded.

5. Check controller (N1) and wiring harness.

Remove the seat assembly in order to access the electronic machine controller (N1). Refer to section Platform Remove (90.110) for procedure.

Inspect the connections of wires 327 (pin 7) and 329 (pin 21) at controller (N1).

Inspect the wiring harness from the controller (N1) to connector (X3).

A. The connections are not secure or the harness is damaged. Repair or replace the connections or harness as required. Confirm that fault code is no longer recorded.

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B. The connections are secure and the harness is free of damage. Replace the controller (N1). Confirm that fault code is no longer recorded.

Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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F27 - Error proportional magent pump forwards Context: Fault code F27 shows on the display unit above the hour counter. The machine does not drive forward, but travel backwards is possible.

Cause: 1. Electrical component failure.

Possible failure modes: 1. Faulty connector (X3).

2. Damaged wiring harness.

3. Faulty PWM pump, forward (Y3).

4. Faulty controller (N1).

Solution: 1. Check connector (X3).

Remove panel from steering column. Refer to section Fuse and relay box - Component localization - Steering column (55.100).

Inspect connector (X3), in particular wires 119 (pin 2) and 121 (pin 3). They should be secure, tight, free of corrosion, abrasion and damage.

A. The connector is secure and the wires at the connector are free of damage. Proceed to step 2.

B. The connector is not secure or the wires are loose or damaged. Repair or replace the connector or wires as required. Confirm that fault code is no longer recorded.

2. Check wiring harness from connector (X3) to PWM pump, forward (Y3).

Inspect the harness. Wires should be free of corrosion, abrasion and damage.

A. The harness is free of damage. Proceed to step 3.

B. The harness is damaged. Replace or replace the harness as required. Confirm that fault code is no longer recorded.

3. Check connections at PWM pump, forward (Y3).

Wires 119 and 121 should be secure, tight, free of corrosion, abrasion or damage.

A. Wires are securely connected and are free of damage. Proceed to step 4.

B. Wires are loose or damaged. Repair or replace as required. Confirm that fault code is no longer recorded.

4. Replace PWM pump, forward (Y3).

A. Fault code is still recorded. Proceed to step 5.

B. Confirm that fault code is no longer recorded.

5. Check controller (N1) and wiring harness.

Remove the seat assembly in order to access the electronic machine controller (N1). Refer to section Platform Remove (90.110) for procedure.

Inspect the connections of wires 320 (pin 3) and 321 (pin 31) at controller (N1).

Inspect the wiring harness from the controller (N1) to connector (X3).

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A. The connections are not secure or the harness is damaged. Repair or replace the connections or harness as required. Confirm that fault code is no longer recorded.

B. The connections are secure and the harness is free of damage. Replace the controller (N1). Confirm that fault code is no longer recorded.

Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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F28 - Error proportional magnet pump backwards Context: Fault code F28 shows on the display unit above the hour counter. The machine does not drive backwards, but travel forward possible.

Cause: 1. Electrical component failure.

Possible failure modes: 1. Faulty connector (X3).

2. Damaged wiring harness.

3. Faulty PWM pump, backward (Y4).

4. Faulty controller (N1).

Solution: 1. Check connector (X3).

Remove panel from steering column. Refer to section Fuse and relay box - Component localization - Steering column (55.100).

Inspect connector (X3), in particular wires 120 (pin 2) and 122 (pin 4). They should be secure, tight, free of corrosion, abrasion and damage.

A. The connector is secure and the wires at the connector are free of damage. Proceed to step 2.

B. The connector is not secure or the wires are loose or damaged. Repair or replace the connector or wires as required. Confirm that fault code is no longer recorded.

2. Check wiring harness from connector (X3) to PWM pump, backward (Y4).

Inspect the harness. Wires should be free of corrosion, abrasion and damage.

A. The harness is free of damage. Proceed to step 3.

B. The harness is damaged. Replace or replace the harness as required. Confirm that fault code is no longer recorded.

3. Check connections at PWM pump, backward (Y4).

Wires 120 and 122 should be secure, tight, free of corrosion, abrasion or damage.

A. Wires are securely connected and are free of damage. Proceed to step 4.

B. Wires are loose or damaged. Repair or replace as required. Confirm that fault code is no longer recorded.

4. Replace PWM pump, backward (Y4).

A. Fault code is still recorded. Proceed to step 5.

B. Confirm that fault code is no longer recorded.

5. Check controller (N1) and wiring harness.

Remove the seat assembly in order to access the electronic machine controller (N1). Refer to section Platform Remove (90.110) for procedure.

Inspect the connections of wires 320 (pin 3) and 322 (pin 30) at controller (N1).

Inspect the wiring harness from the controller (N1) to connector (X3).

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A. The connections are not secure or the harness is damaged. Repair or replace the connections or harness as required. Confirm that fault code is no longer recorded.

B. The connections are secure and the harness is free of damage. Replace the controller (N1). Confirm that fault code is no longer recorded.

Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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F29 - Error switching magnet vibration relay Context: Fault code F29 shows on the display unit above the hour counter. Vibration is no longer actuated.

Cause: 1. Electrical component failure.

Possible failure modes: 1. Faulty connector (X1).

2. Faulty vibration relay (K4).

3. Faulty controller (N1).

Solution: 1. Check connector (X1).

Remove panel from steering column. Refer to section Fuse and relay box - Component localization - Steering column (55.100).

Inspect connector (X1). It should be secure, tight, free of corrosion, abrasion and damage.

A. The connector is secure and the wires at the connector are free of damage. Proceed to step 2.

B. The connector is not secure or the wires are loose or damaged. Repair or replace the connector or wires as required. Confirm that fault code is no longer recorded.

2. Check vibration relay (K4).

Remove panel from steering column. Refer to section Fuse and relay box - Component localization - Steering column (55.100).

Inspect vibration relay (K4). All pins should be secure, tight, free of corrosion, abrasion and damage.

Using an ohmmeter, measure the resistance between pins 85 and 86. The resistance should be between 70 Ω and 100 Ω.

A. Pins are secure, tight, free of corrosion, abrasion and damage and measured resistance is between 70 Ω and 100 Ω. Proceed to step 3.

B. Pins are damaged or measured resistance is less then 70 Ω or more than 100 Ω. Replace vibration relay (K4).

Confirm that fault code is no longer recorded.

3. Check controller (N1) and wiring harness.

Remove the seat assembly in order to access the electronic machine controller (N1). Refer to section Platform Remove (90.110) for procedure.

Inspect the connection of wire 385 (pin 15) at controller (N1).

Inspect the wiring harness from the controller (N1) to connector (X1).

A. The connections are not secure or the harness is damaged. Repair or replace the connections or harness as required. Confirm that fault code is no longer recorded.

B. The connections are secure and the harness is free of damage. Replace the controller (N1). Confirm that fault code is no longer recorded.

Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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F30 - Error switching magnet brake valve Context: Fault code F30 shows on the display unit above the hour counter. The vehicle is not driving.

Cause: 1. Electrical component failure.

Possible failure modes: 1. Faulty connector (X1).

2. Faulty brake valve (Y2).

3. Faulty parking brake switch (S17).

Solution: 1. Check connector (X1).

Remove panel from steering column. Refer to section Fuse and relay box - Component localization - Steering column (55.100).

Inspect connector (X1), in particular wire103 (pin 3) and the harness. They should be secure, tight, free of corrosion, abrasion and damage.

A. The connector is secure and the harness is free of damage. Proceed to step 2.

B. The connector is not secure or the harness is damaged. Replace the connector or harness as required. Confirm that fault code is no longer recorded.

2. Check locking brake valve (Y2).

Inspect locking brake valve (Y2), the wire connections and the harness. They should be secure, tight, free of corrosion, abrasion and damage.

A. The valve and the harness are free of damage and the wires are connected securely. Proceed to step 3.

B. The valve or the harness is damaged or the connections are not secure. Replace or repair the connections, valve or harness as required. Confirm that fault code is no longer recorded.

3. Check the parking brake switch (S17) and harness.

Refer to section Armrest control panel - Component identification (55.512).

Remove the side panel of the armrest control panel to access the components under the operating lever.

Inspect the parking brake switch (S17) and the harness. They should be secure, tight, free of corrosion, abrasion and damage.

A. The switch and the harness are free of damage. Proceed to step 4.

B. The switch or the harness is damaged. Replace the switch or harness as required. Confirm that fault code is no longer recorded.

4. Check controller (N1) and wiring harness.

Remove the seat assembly in order to access the electronic machine controller (N1). Refer to section Platform Remove (90.110) for procedure.

Inspect the connections of wires 387 (pin 29) and 388 (pin 33) at controller (N1).

Inspect the wiring harness from the controller (N1) to the parking brake switch (S17)

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A. The connections are not secure or the harness is damaged. Repair or replace the connections or harness as required. Confirm that fault code is no longer recorded.

B. The connections are secure and the harness is free of damage. Replace the controller (N1). Confirm that fault code is no longer recorded.

Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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F31 - Battery voltage too low Context: Fault code F31 shows on the display unit above the hour counter. The vehicle is not driving.

Cause: 1. Battery voltage is less than 7 V. Possible failure modes: 1. Problems with battery or charging system.

2. Faulty Fuse (F10).

3. Faulty controller (N1).

Solution: 1. Verify that connectors are free of damage.

Inspect the alternator (G1) and battery (G2) connections. All connections should be secure, tight, free of corrosion, abrasion and damage.

A. All connectors are secure. Go to step 2.

B. The connectors are loose or damaged. Repair or replace the connectors as required. Confirm that fault code is no longer recorded.

2. Check fuse (F10).

Inspect fuse (F10). Refer to section Fuse and relay box - Component localization - Steering column (55.100).

A. The fuse is not defective. Proceed to step 3.

B. The fuse is defective. Replace the fuse. Confirm that fault code is no longer recorded.

3. Check if the machine power supply is > 12 V. A. The machine power supply is > 12 V. Go to step 4.

B. The machine power supply is less than 12 V. Replace the battery. Confirm that fault code is no longer recorded.

4. Check controller (N1) and wiring harness.

Remove the seat assembly in order to access the electronic machine controller (N1). Refer to section Platform Remove (90.110) for procedure.

Inspect the connections at controller (N1).

Inspect the wiring harness from the controller (N1).

A. The connections are not secure or the harness is damaged. Repair or replace the connections or harness as required. Confirm that fault code is no longer recorded.

B. The connections are secure and the harness is free of damage. Replace the controller (N1). Confirm that fault code is no longer recorded.

Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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F32 - Oil temperature too high Context: Fault code F32 shows on the display unit above the hour counter. The machine can only be driven at 1 km/h (0.62 mph). The vibration function can no longer be switched on.

Cause: 1. Hydraulic oil temperature is higher than the set emergency driving temperature 95 °C (203 °F).

Possible failure modes: 1. Faulty hydraulic oil cooler.

2. Faulty hydraulic oil cooler fan (M2).

3. Faulty fuse (F15).

4. Faulty hydraulic oil cooler relay (K5).

5. Faulty temperature sensor (S53).

Solution: 1. Clean the hydraulic oil cooler radiator (located under the driver’s floor panel).

Check the cooling ribs of the hydraulic oil cooler for dirt and clogging.

Clean the ribs with water or blow them out with compressed air.

A. Hydraulic oil cooler radiator is clean, but fault code is still recorded. Go to step 2.

B. Hydraulic oil cooler radiator is clean and fault code is not recorded again and no longer active. OK to return the machine to service.

2. Check the hydraulic oil cooler fan (M2).

Check connections from connector (X1) to hydraulic oil cooler fan (M2). All connections should be secure, tight, free of corrosion, abrasion and damage.

A. Hydraulic oil cooler fan (M2) is functioning and connections are secure. Go to step 3.

B. Hydraulic oil cooler fan (M2) is not functioning or connections are not secure. Repair or replace components as required. Confirm that fault code is no longer recorded.

3. Check the fuse (F15).

Inspect fuse (F15). Refer to section Fuse and relay box - Component localization - Steering column (55.100).

A. The fuse is not defective. Proceed to step 4.

B. The fuse is defective. Replace the fuse. Confirm that fault code is no longer recorded.

4. Check hydraulic oil cooler relay (K5).

Remove panel from steering column. Refer to section Fuse and relay box - Component localization - Steering column (55.100).

Inspect hydraulic oil cooler relay (K5). All pins should be secure, tight, free of corrosion, abrasion and damage.

Using an ohmmeter, measure the resistance between pins 85 and 86. The resistance should be between 70 Ω and 100 Ω.

A. Pins are secure, tight, free of corrosion, abrasion and damage and measured resistance is between 70 Ω and 100 Ω. Proceed to step 5.

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B. Pins are damaged or measured resistance is less then 70 Ί or more than 100 Ί. Replace hydraulic oil cooler relay (K5). Confirm that fault code is no longer recorded.

5. Check connector (X3).

Remove panel from steering column. Refer to section Fuse and relay box - Component localization - Steering column (55.100).

Inspect connector (X3), in particular wires 126 (pin 8) and 127 (pin 9). They should be secure, tight, free of corrosion, abrasion and damage.

A. The connector is secure and the wires are free of damage. Proceed to step 6.

B. The connector is not secure or the wires are damaged. Replace or repair the connector or wires as required.

Confirm that fault code is no longer recorded.

6. Check hydraulic oil temperature sensor (S53).

Inspect hydraulic oil temperature sensor (S53) and all connections. They should be secure, tight, free of corrosion, abrasion and damage.

A. The sensor and the connections are free of damage. Proceed to step 7.

B. The sensor or the connections are damaged. Replace or repair the sensor or connections as required. Confirm that fault code is no longer recorded.

7. Check controller (N1) and wiring harness.

Remove the seat assembly in order to access the electronic machine controller (N1). Refer to section Platform Remove (90.110) for procedure.

Inspect the connections of wires 327 (pin 7) and 329 (pin 21) at controller (N1).

Inspect the wiring harness from the controller (N1) to the hydraulic oil temperature sensor (S53).

A. The connections are not secure or the harness is damaged. Repair or replace the connections or harness as required. Confirm that fault code is no longer recorded.

B. The connections are secure and the harness is free of damage. Replace the controller (N1). Confirm that fault code is no longer recorded.

Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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F33 - Internal power supply outside permissible range Context: Fault code F33 shows on the display unit above the hour counter. The vehicle is not reacting.

Cause: 1. The 8 V internal power supply is outside the permissible range.

Possible failure modes: 1. Faulty fuse (F10) 2. Faulty controller (N1) Solution: 1. Check fuse (F10).

Inspect fuse (F10). Refer to section Fuse and relay box - Component localization - Steering column (55.100).

A. The fuse is not defective. Proceed to step 2.

B. The fuse is defective. Replace the fuse. Confirm that fault code is no longer recorded.

2. Check if the internal power supply 8 V is outside the permissible range.

A. The internal power supply is inside the permissible range. Go to step 3.

B. The internal power supply is outside the permissible range. Repair or replace power supply as required. Confirm that fault code is no longer recorded.

3. Check if the machine power supply is > 12 V. A. The machine power supply is > 12 V. Go to step 4.

B. The machine power supply is less than 12 V. Replace the battery. Confirm that fault code is no longer recorded.

4. Check controller (N1) and wiring harness.

Remove the seat assembly in order to access the electronic machine controller (N1). Refer to section Platform Remove (90.110) for procedure.

Inspect the connections at controller (N1).

Inspect the wiring harness from the controller (N1).

A. The connections are not secure or the harness is damaged. Repair or replace the connections or harness as required. Confirm that fault code is no longer recorded.

B. The connections are secure and the harness is free of damage. Replace the controller (N1). Confirm that fault code is no longer recorded.

Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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F33 - Internal power supply outside permissible range Context: Fault code F34 shows on the display unit above the hour counter. The vehicle is not driving.

Cause: 1. The 2.5 V internal power supply is outside the permissible range.

Possible failure modes: 1. Faulty fuse (F10) 2. Faulty controller (N1) Solution: 1. Check fuse (F10).

Inspect fuse (F10). Refer to section Fuse and relay box - Component localization - Steering column (55.100).

A. The fuse is not defective. Proceed to step 2.

B. The fuse is defective. Replace the fuse. Confirm that fault code is no longer recorded.

2. Check if the internal power supply 2.5 V is outside the permissible range.

A. The internal power supply is inside the permissible range. Go to step 3.

B. The internal power supply is outside the permissible range. Repair or replace power supply as required. Confirm that fault code is no longer recorded.

3. Check if the machine power supply is > 12 V. A. The machine power supply is > 12 V. Go to step 4.

B. The machine power supply is less than 12 V. Replace the battery. Confirm that fault code is no longer recorded.

4. Check controller (N1) and wiring harness.

Remove the seat assembly in order to access the electronic machine controller (N1). Refer to section Platform Remove (90.110) for procedure.

Inspect the connections at controller (N1).

Inspect the wiring harness from the controller (N1).

A. The connections are not secure or the harness is damaged. Repair or replace the connections or harness as required. Confirm that fault code is no longer recorded.

B. The connections are secure and the harness is free of damage. Replace the controller (N1). Confirm that fault code is no longer recorded.

Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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F35 - Restricted ability of pump to be switched off Context: Fault code F35 shows on the display unit above the hour counter. The machine does not drive. No outputs are actuated, only the digits of the display unit are actuated.

Cause: 1. Electrical component failure.

Possible failure modes: 1. Faulty drive pump magnets (Y3) and (Y4).

2. Faulty controller (N1).

Solution: 1. Check the connectors on the pump magnets (Y3) and (Y4).

Wires 119, 121 to pump magnet (Y3) and wires 120, 122 to pump magnet (Y4) should be secure, tight, free of corrosion, abrasion or damage.

A. Wires are securely connected and are free of damage. Proceed to step 2.

B. Wires are loose or damaged. Repair or replace as required. Confirm that fault code is no longer recorded.

2. Test the solenoids.

Remove the solenoids from the drive pump and unscrew the solenoid valve.

Measure each solenoid’s resistance with an ohmmeter. The resistance should be approximately 6 Ω.

Apply a voltage of 12 V to each solenoid valve and watch the valve to be visibly actuated.

A. The measured resistance is 6 Ω and the solenoid does actuate once a voltage of 12 V is applied. Go to step 3.

B. The measured resistance is not 6 Ω or the solenoid does not actuate once a voltage of 12 V is applied. Replace the faulty solenoid. Confirm that fault code is no longer recorded.

3. Check controller (N1) and wiring harness.

Remove the seat assembly in order to access the electronic machine controller (N1). Refer to section Platform Remove (90.110) for procedure.

Inspect the connections of wires 320 (pin 3), 321 (pin 31) and 322 (pin 30) at controller (N1).

Inspect the wiring harness from the controller (N1) to connector (X3).

A. The connections are not secure or the harness is damaged. Repair or replace the connections or harness as required. Confirm that fault code is no longer recorded.

B. The connections are secure and the harness is free of damage. Replace the controller (N1). Confirm that fault code is no longer recorded.

Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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Electrical systems - FAULT CODES

F36 - Pump magnet forwards failure Context: Fault code F36 shows on the display unit above the hour counter. The machine does not drive.

Cause: 1. Electrical component failure.

Possible failure modes: 1. Faulty drive pump magnet (Y3).

2. Faulty controller (N1).

Solution: 1. Check the connectors on the pump magnet (Y3).

Wires 119 and 121 to pump magnet (Y3) should be secure, tight, free of corrosion, abrasion or damage.

A. Wires are securely connected and are free of damage. Proceed to step 2.

B. Wires are loose or damaged. Repair or replace as required. Confirm that fault code is no longer recorded.

2. Test the solenoid.

Remove the solenoid from the drive pump and unscrew the solenoid valve.

Measure the solenoid’s resistance with an ohmmeter. The resistance should be approximately 6 Ω.

Apply a voltage of 12 V to the solenoid valve and watch the valve to be visibly actuated.

A. The measured resistance is 6 Ω and the solenoid does actuate once a voltage of 12 V is applied. Go to step 3.

B. The measured resistance is not 6 Ω or the solenoid does not actuate once a voltage of 12 V is applied. Replace the faulty solenoid. Confirm that fault code is no longer recorded.

3. Check controller (N1) and wiring harness.

Remove the seat assembly in order to access the electronic machine controller (N1). Refer to section Platform Remove (90.110) for procedure.

Inspect the connections of wires 320 (pin 3) and 321 (pin 31) at controller (N1).

Inspect the wiring harness from the controller (N1) to connector (X3).

A. The connections are not secure or the harness is damaged. Repair or replace the connections or harness as required. Confirm that fault code is no longer recorded.

B. The connections are secure and the harness is free of damage. Replace the controller (N1). Confirm that fault code is no longer recorded.

Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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Electrical systems - FAULT CODES

F37 - Pump magnet backwards failure Context: Fault code F36 shows on the display unit above the hour counter. The machine does not drive.

Cause: 1. Electrical component failure.

Possible failure modes: 1. Faulty drive pump magnet (Y4).

2. Faulty controller (N1).

Solution: 1. Check the connectors on the pump magnet (Y4).

Wires 120 and 122 to pump magnet (Y4) should be secure, tight, free of corrosion, abrasion or damage.

A. Wires are securely connected and are free of damage. Proceed to step 2.

B. Wires are loose or damaged. Repair or replace as required. Confirm that fault code is no longer recorded.

2. Test the solenoid.

Remove the solenoid from the drive pump and unscrew the solenoid valve.

Measure the solenoid’s resistance with an ohmmeter. The resistance should be approximately 6 Ω.

Apply a voltage of 12 V to the solenoid valve and watch the valve to be visibly actuated.

A. The measured resistance is 6 Ω and the solenoid does actuate once a voltage of 12 V is applied. Go to step 3.

B. The measured resistance is not 6 Ω or the solenoid does not actuate once a voltage of 12 V is applied. Replace the faulty solenoid. Confirm that fault code is no longer recorded.

3. Check controller (N1) and wiring harness.

Remove the seat assembly in order to access the electronic machine controller (N1). Refer to section Platform Remove (90.110) for procedure.

Inspect the connections of wires 320 (pin 3) and 322 (pin 30) at controller (N1).

Inspect the wiring harness from the controller (N1) to connector (X3).

A. The connections are not secure or the harness is damaged. Repair or replace the connections or harness as required. Confirm that fault code is no longer recorded.

B. The connections are secure and the harness is free of damage. Replace the controller (N1). Confirm that fault code is no longer recorded.

Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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Electrical systems - FAULT CODES

F38 - Wrong direction of travel Context: Fault code F38 shows on the display unit above the hour counter and prevents driving of the machine.

Cause: 1. Electrical component failure, usually a defective operating lever.

2. If the problem only occurs sporadically, the cause is probably the operating lever(s). Otherwise the controller is defective.

Possible failure modes: 1. Faulty operating lever, right 2. Faulty operating lever, left (if equipped) 3. Faulty controller (N1) Solution: 1. Check connector in right armrest control panel.

Refer to section Armrest control panel - Component identification (55.512).

Remove the side panel of the right armrest control panel to access the connectors under the right operating lever.

Inspect the 6–pin connector with wires 901, 903, 911, 914 and 915 and the harness. They should be secure, tight, free of corrosion, abrasion and damage.

A. The connector is secure and the harness is free of damage. Proceed to step 2.

B. The connector is not secure or the harness is damaged. Replace the connector or harness as required. Confirm that fault code is no longer recorded.

2. Check the right operating lever and potentiometer switch (S3).

Release the rubber boot at the bottom of he right operating lever and remove the 4 screws. Refer to section Operator platform less cab - Replace Operating lever (90.110).

Remove the operating lever assembly to gain access to the potentiometer switch (S3) at the bottom of the operating lever.

Inspect the wires connected to the potentiometer switch (S3) and he harness. They should be secure, tight, free of corrosion, abrasion and damage.

Make sure that the bolt that is in contact with the potentiometer switch (S3) is securely attached to the lever.

A. The wires are securely connected to he potentiometer switch (S3), the harness is free of damage and the bolt is securely attached to the lever. Proceed to step 3.

B. The wires are not securely connected to he potentiometer switch (S3), the harness is damaged or the bolt is loose. Repair or replace components as required. Confirm that fault code is no longer recorded.

3. Replace the right operating lever.

A. The fault code is still recorded. Proceed to step 4.

B. The fault code is no longer recorded. Proceed to start the engine.

4. Check connector in left armrest control panel.

Refer to section Armrest control panel - Component identification (55.512).

Remove the side panel of the left armrest control panel to access the connectors under the operating lever.

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Electrical systems - FAULT CODES

Inspect the 6–pin connector with wires 902, 904, 913, 919 and 920 and the harness. They should be secure, tight, free of corrosion, abrasion and damage.

A. The connector is secure and the harness is free of damage. Proceed to step 5.

B. The connector is not secure or the harness is damaged. Replace the connector or harness as required. Confirm that fault code is no longer recorded.

5. Check the left operating lever and potentiometer switch (S15).

Release the rubber boot at the bottom of he left operating lever and remove the 4 screws. Refer to section Operator platform less cab - Replace Operating lever (90.110).

Remove the operating lever assembly to gain access to the potentiometer switch (S15) at the bottom of the operating lever.

Inspect the wires connected to the potentiometer switch (S15) and he harness. They should be secure, tight, free of corrosion, abrasion and damage.

Make sure that the bolt that is in contact with the potentiometer switch (S15) is securely attached to the lever.

A. The wires are securely connected to he potentiometer switch (S15), the harness is free of damage and the bolt is securely attached to the lever. Proceed to step 6.

B. The wires are not securely connected to he potentiometer switch (S15), the harness is damaged or the bolt is loose. Repair or replace components as required. Confirm that fault code is no longer recorded.

6. Replace the left operating lever.

A. The fault code is still recorded. Proceed to step 7.

B. The fault code is no longer recorded. Proceed to start the engine.

7. Check electronic machine controller (N1) and wiring harness.

Remove the seat assembly in order to access the electronic machine controller (N1). Refer to section Platform Remove (90.110) for procedure.

Unplug the harness coming from connector (X50).

Disconnect wires 366 (pin 36) and 369 (pin 11) from that plug.

Measure the resistance between the end of wire 366 (pin 36) and the end of wire 369 (pin 11). The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.

Disconnect wires 366 (pin 36) and 370 (pin 34) from that plug.

Measure the resistance between the end of wire 366 (pin 36) and the end of wire 370 (pin 34). The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.

A. The resistance is less than 10 Ω. Replace the electronic machine controller (N1). Confirm that fault code is no longer recorded.

B. The resistance is greater than 20,000 Ω. There is a short circuit in the wiring. Repair or replace the harness as required. Confirm that fault code is no longer recorded.

Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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Electrical systems - FAULT CODES

F39 - Flow with operating lever in neutral Context: Fault code F39 shows on the display unit above the hour counter and prevents driving of the machine.

Cause: 1. Drive pump current does not decrease to the required extent when operating lever neutral switch signals neutral.

2. Electrical component failure, usually a defective operating lever.

3. If the problem only occurs sporadically, the cause is probably the operating lever(s). Otherwise the controller is defective.

Possible failure modes: 1. Faulty operating lever right (S3) 2. Faulty operating lever left (S15) 3. Faulty controller (N1) Solution: 1. Check connector in right armrest control panel.

Refer to section Armrest control panel - Component identification (55.512).

Remove the side panel of the right armrest control panel to access the connectors under the right operating lever.

Inspect the 6–pin connector with wires 901, 903, 911, 914 and 915 and the harness. They should be secure, tight, free of corrosion, abrasion and damage.

A. The connector is secure and the harness is free of damage. Proceed to step 2.

B. The connector is not secure or the harness is damaged. Replace the connector or harness as required. Confirm that fault code is no longer recorded.

2. Check the right operating lever and potentiometer switch (S3).

Release the rubber boot at the bottom of he right operating lever and remove the 4 screws. Refer to section Operator platform less cab - Replace Operating lever (90.110).

Remove the operating lever assembly to gain access to the potentiometer switch (S3) at the bottom of the operating lever.

Inspect the wires connected to the potentiometer switch (S3) and he harness. They should be secure, tight, free of corrosion, abrasion and damage.

Make sure that the bolt that is in contact with the potentiometer switch (S3) is securely attached to the lever.

A. The wires are securely connected to he potentiometer switch (S3), the harness is free of damage and the bolt is securely attached to the lever. Proceed to step 3.

B. The wires are not securely connected to he potentiometer switch (S3), the harness is damaged or the bolt is loose. Repair or replace components as required. Confirm that fault code is no longer recorded.

3. Replace the right operating lever.

A. The fault code is still recorded. Proceed to step 4.

B. The fault code is no longer recorded. Proceed to start the engine.

4. Check connector in left armrest control panel.

Refer to section Armrest control panel - Component identification (55.512).

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Electrical systems - FAULT CODES

Remove the side panel of the left armrest control panel to access the connectors under the operating lever.

Inspect the 6–pin connector with wires 902, 904, 913, 919 and 920 and the harness. They should be secure, tight, free of corrosion, abrasion and damage.

A. The connector is secure and the harness is free of damage. Proceed to step 5.

B. The connector is not secure or the harness is damaged. Replace the connector or harness as required. Confirm that fault code is no longer recorded.

5. Check the left operating lever and potentiometer switch (S15).

Release the rubber boot at the bottom of he left operating lever and remove the 4 screws. Refer to section Operator platform less cab - Replace Operating lever (90.110).

Remove the operating lever assembly to gain access to the potentiometer switch (S15) at the bottom of the operating lever.

Inspect the wires connected to the potentiometer switch (S15) and he harness. They should be secure, tight, free of corrosion, abrasion and damage.

Make sure that the bolt that is in contact with the potentiometer switch (S15) is securely attached to the lever.

A. The wires are securely connected to he potentiometer switch (S15), the harness is free of damage and the bolt is securely attached to the lever. Proceed to step 6.

B. The wires are not securely connected to he potentiometer switch (S15), the harness is damaged or the bolt is loose. Repair or replace components as required. Confirm that fault code is no longer recorded.

6. Replace the left operating lever.

A. The fault code is still recorded. Proceed to step 7.

B. The fault code is no longer recorded. Proceed to start the engine.

7. Check electronic machine controller (N1) and wiring harness.

Remove the seat assembly in order to access the electronic machine controller (N1). Refer to section Platform Remove (90.110) for procedure.

Unplug the harness coming from connector (X50).

Disconnect wires 366 (pin 36) and 369 (pin 11) from that plug.

Measure the resistance between the end of wire 366 (pin 36) and the end of wire 369 (pin 11). The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.

Disconnect wires 366 (pin 36) and 370 (pin 34) from that plug.

Measure the resistance between the end of wire 366 (pin 36) and the end of wire 370 (pin 34). The resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.

A. The resistance is less than 10 Ω. Replace the electronic machine controller (N1). Confirm that fault code is no longer recorded.

B. The resistance is greater than 20,000 Ω. There is a short circuit in the wiring. Repair or replace the harness as required. Confirm that fault code is no longer recorded.

Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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Electrical systems - FAULT CODES

F40 - Program sequence failure Context: Fault code F40 shows on the display unit above the hour counter. The vehicle is not driving.

Cause: 1. The controller (N1) has not processed the program correctly.

Possible failure modes: 1. Faulty fuse (F10) 2. Faulty controller (N1) Solution: 1. Check fuse (F10).

Inspect fuse (F10). Refer to section Fuse and relay box - Component localization - Steering column (55.100).

A. The fuse is not defective. Proceed to step 2.

B. The fuse is defective. Replace the fuse. Confirm that fault code is no longer recorded.

2. Check if the machine power supply is > 12 V. A. The machine power supply is > 12 V. Go to step 3.

B. The machine power supply is less than 12 V. Replace the battery. Confirm that fault code is no longer recorded.

3. Check controller (N1) and wiring harness.

Remove the seat assembly in order to access the electronic machine controller (N1). Refer to section Platform Remove (90.110) for procedure.

Inspect the connections at controller (N1).

Inspect the wiring harness from the controller (N1).

A. The connections are not secure or the harness is damaged. Repair or replace the connections or harness as required. Confirm that fault code is no longer recorded.

B. The connections are secure and the harness is free of damage. Replace the controller (N1). Confirm that fault code is no longer recorded.

Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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Electrical systems - FAULT CODES

F41 - Starting condition failure Context: Fault code F41 shows on the display unit above the hour counter. The vehicle is not driving. No outputs are actuated, only the digits of the display unit are actuated.

Cause: 1. Electrical component failure.

Possible failure modes: 1. Faulty fuse (F10) 2. Faulty controller (N1) Solution: 1. Check fuse (F10).

Inspect fuse (F10). Refer to section Fuse and relay box - Component localization - Steering column (55.100).

A. The fuse is not defective. Proceed to step 2.

B. The fuse is defective. Replace the fuse. Confirm that fault code is no longer recorded.

2. Check if the machine power supply is > 12 V. A. The machine power supply is > 12 V. Go to step 3.

B. The machine power supply is less than 12 V. Replace the battery. Confirm that fault code is no longer recorded.

3. Check controller (N1) and wiring harness.

Remove the seat assembly in order to access the electronic machine controller (N1). Refer to section Platform Remove (90.110) for procedure.

Inspect the connections at controller (N1).

Inspect the wiring harness from the controller (N1).

A. The connections are not secure or the harness is damaged. Repair or replace the connections or harness as required. Confirm that fault code is no longer recorded.

B. The connections are secure and the harness is free of damage. Replace the controller (N1). Confirm that fault code is no longer recorded.

Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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Electrical systems - FAULT CODES

F42 - Asphalt temperature sensor failure Context: Fault code F42 shows on the display unit above the hour counter. No temperature display.

Cause: 1. Short circuit or interruption of asphalt temperature sensor.

Possible failure modes: 1. Faulty fuse (F14).

2. Faulty asphalt temperature sensor (N3).

3. Faulty connector to controller.

Solution: 1. Check fuse (F14).

Inspect fuse (F14). Refer to section Fuse and relay box - Component localization - Steering column (55.100).

A. The fuse is not defective. Proceed to step 2.

B. The fuse is defective. Replace the fuse. Confirm that fault code is no longer recorded.

2. Check the asphalt temperature sensor (N3).

A. The sensor is not defective. Proceed to step 3.

B. The sensor is defective. Replace the sensor. Confirm that fault code is no longer recorded.

3. Check controller (N1) and wiring harness.

Remove the seat assembly in order to access the electronic machine controller (N1). Refer to section Platform Remove (90.110) for procedure.

Inspect the connections at controller (N1).

Inspect the wiring harness from the controller (N1).

A. The connections are not secure or the harness is damaged. Repair or replace the connections or harness as required. Confirm that fault code is no longer recorded.

B. The connections are secure and the harness is free of damage. Replace the controller (N1). Confirm that fault code is no longer recorded.

Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 01 (55.100.DP-C.20.E.01) Wiring harnesses - Electrical schematic sheet 02 (55.100.DP-C.20.E.02)

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Index Electrical systems - 55 FAULT CODES - DTC -11 - Seat contact open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

-12 - Operating lever is deflected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

-13 - Both operating levers are deflected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

-14 - Parking brake is activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

-15 - Engine is not running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

BUS - No data from CAN bus to the display unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

F21 - Error operating lever right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

F22 - Operating lever right neutral signal does not match operating lever signal . . . . . . . . . . . . . . . .

16

F23 - Error operating lever left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

F24 - Operating lever left neutral signal does not match operating lever signal . . . . . . . . . . . . . . . . .

20

F25 - Sprinkler potentiometer error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

F26 - Resistance outside permissible range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

F27 - Error proportional magent pump forwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

F28 - Error proportional magnet pump backwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

F29 - Error switching magnet vibration relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29

F30 - Error switching magnet brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30

F31 - Battery voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32

F32 - Oil temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33

F33 - Internal power supply outside permissible range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35

F33 - Internal power supply outside permissible range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36

F35 - Restricted ability of pump to be switched off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37

F36 - Pump magnet forwards failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38

F37 - Pump magnet backwards failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39

F38 - Wrong direction of travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40

F39 - Flow with operating lever in neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42

F40 - Program sequence failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44

F41 - Starting condition failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45

F42 - Asphalt temperature sensor failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404

SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. Š 2017 CNH Industrial America LLC. All rights reserved.

No part of the text or illustrations of this publication may be reproduced.

CNH Industrial America LLC reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at the time of publication, but are subject to change without notice.

Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your CASE CONSTRUCTION dealer.

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

Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.

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SERVICE MANUAL Tools DV23CC DV23 DV26CC DV26

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Contents Tools - 89

[89.165] Water kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89.1

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Tools - 89 Water kit - 165

DV23CC DV23 DV26CC DV26

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Contents Tools - 89 Water kit - 165

FUNCTIONAL DATA Reservoir Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Reservoir Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Tools - Water kit

Reservoir - Component identification

SS13A778

1

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Tools - Water kit

Pos. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Designation Water tank Fuel filler cap Fuel tank filter Filling level indicator Oval head screw Mounting plate Cable Washer Hexagon head screw Adhesive clip Washer Socket head cap screw Washer Holding plate Washer Hexagon head screw

Pos. 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

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Designation Screwed elbow socket Adhesive Jointing compound Rubber mat Fuel filler cap O-ring Hexagon head screw Washer Intermediate part Intermediate part Screwed elbow socket Shut-off valve Double nipple Rubber cushion Adjustable male stud run Water pump

Tools - Water kit

Reservoir - Drain fluid 1. Unscrew the water drain’s screw plug (1) with a wrench or with the “Service assembly tool”.

SS13A696

1

2. Drain off the water.

NOTICE: In the event of the risk of frost, additionally drain the sprinkler system. Refer to Winterization, see “operations manual”.

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Tools - Water kit

Reservoir - Remove Prior operation: Drain the reservoir. Refer to Reservoir - Drain fluid (89.165).

1. Disconnect the three water lines (1).

2. Disconnect the connector (M4) from the water pump.

3. Disconnect the connector (Y9) from the shutoff valve.

SVIL13COM0366AB

1

SVIL13COM0367AB

2

SVIL13COM0369AB

3

4. Remove the hexagon bolts and the rubber element.

5. Remove the hexagon bolts and the spacer plate.

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Tools - Water kit

6. Remove the hexagon bolts on the rear water tank bracket.

SVIL13COM0371AB

4

SVIL13COM0373AB

5

SVIL13COM0375AB

6

SVIL13COM0377AB

7

7. Disconnect the water line.

8. Disconnect the connectors (E21, E22, X16, and X21).

9. Screw an eye bolt M8 into the corresponding inner thread in the front.

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Tools - Water kit

10. You can now lift out the water tank carefully.

SVIL13COM0378AB

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8

Tools - Water kit

Reservoir - Install 1. Screw an eye bolt into the corresponding inner thread in the front.

SVIL13COM0377AB

1

SVIL13COM0378AB

2

SVIL13COM0375AB

3

SVIL13COM0373AB

4

2. Lift in the water tank.

3. Connect the (X21, E21, E22 and X16) connectors.

4. Connect the water line.

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Tools - Water kit

5. Apply LOCTITE® 242® to the hexagon bolts on the rear water tank bracket.

6. Torque the hexagon bolts to 25.0 N·m (18.4 lb ft).

SVIL13COM0371AB

5

SVIL13COM0369AB

6

SVIL13COM0367AB

7

SVIL13COM0366AB

8

7. Install the hexagon bolts and the spacer plate.

8. Apply LOCTITE® 242® to the hexagon bolts.

9. Torque the bolts to 25.0 N·m (18.4 lb ft).

10. Install the hexagon bolts and the rubber element.

11. Apply LOCTITE® 242® to the hexagon bolts.

12. Torque the bolts to 84 N·m (62 lb ft) .

13. Connect the connector (Y9) with the shutoff valve.

14. Connect the connector (M4) with the water pump.

15. Connect the three water lines (1).

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Index Tools - 89 Water kit - 165 Reservoir - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Reservoir - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Reservoir - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Reservoir - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404

SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. Š 2017 CNH Industrial America LLC. All rights reserved.

No part of the text or illustrations of this publication may be reproduced.

CNH Industrial America LLC reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at the time of publication, but are subject to change without notice.

Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your CASE CONSTRUCTION dealer.

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

Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.

48142067 15/09/2017 EN

SERVICE MANUAL Platform, cab, bodywork, and decals DV23CC DV23 DV26CC DV26

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90

Contents Platform, cab, bodywork, and decals - 90

[90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 [90.110] Operator platform less cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2

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Platform, cab, bodywork, and decals - 90 Engine hood and panels - 100

DV23CC DV23 DV26CC DV26

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Contents Platform, cab, bodywork, and decals - 90 Engine hood and panels - 100

SERVICE Hood Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Replace - Hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Replace Gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Depressurising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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Platform, cab, bodywork, and decals - Engine hood and panels

Hood - Remove WARNING Rotating parts!

Shut off the engine before opening the engine hood.

Failure to comply could result in death or serious injury.

W1059A

WARNING Hot surface possible!

Wait for all components to cool before performing any operation.

Failure to comply could result in death or serious injury.

SS13A699

1

SS13A700

2

W0251A

There is a locking device on both sides of the roller.

1.

Open the catches on both sides.

2.

Open the hood with the handle on the left of the hood.

3.

Lift the hood with slight pressure toward the center of the roller.

If you wish to secure the engine compartment from unauthorized access by third parties, you can install a padlock on the loops provided for this purpose. • Commercially available padlocks can be obtained in any building supplies store.

NOTE: Two gas struts reduce the force required to open the hood and give it its final position. If you need more force to open the hood, replace the gas struts. Refer to Hood - Replace Gas strut (90.100).

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Platform, cab, bodywork, and decals - Engine hood and panels

Removing the hood 1. Use a C-clamp and two pieces of wood to create a lifting point.

2. Attach the sling to the C-clamp.

SVIL13COM0344AB

3

SVIL13COM0345AB

4

SVIL13COM0346AB

5

SVIL13COM0347AC

6

3. Use a screwdriver to lift the clips.

4. Pull the gas strut away from the ball joint.

5. Disconnect the lights from the electrical system.

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6. Use a crane to lift the hood up.

SVIL13COM0348AB

7

SVIL13COM0349AB

8

SVIL13COM0350AB

9

7. Remove the screws of the hinges.

8. You can now use the crane to completely remove the hood from the chassis.

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Platform, cab, bodywork, and decals - Engine hood and panels

Hood - Install WARNING Hot surface possible!

Wait for all components to cool before performing any operation.

Failure to comply could result in death or serious injury.

W0251A

1. Use a C-clamp and two pieces of wood to create a lifting point.

2. Attach the sling to the C-clamp.

SVIL13COM0344AB

1

SVIL13COM0345AB

2

SVIL13COM0350AB

3

3. Use the crane to put the hood on the chassis.

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Platform, cab, bodywork, and decals - Engine hood and panels

4. Apply LOCTITE® 242® to the screws of the hinges.

5. Torque the screws to 10.0 N·m (7.4 lb ft).

SVIL13COM0349AB

4

SVIL13COM0347AC

5

SVIL13COM0346AD

6

6. Connect the lights with the electrical system.

7. Put the gas strut to the ball joint.

8. Install the clips.

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Platform, cab, bodywork, and decals - Engine hood and panels

Hood - Replace - Hinges Prior operation: Hood - Remove (90.100)

Replacing the hinges 1. Remove the hexagon bolts.

2. Replace the hinge.

3. Apply LOCTITE® 242® to the bolts and screw them back in with a torque of 10 N·m (7.4 lb ft).

SVIL13COM0649AB

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1

Platform, cab, bodywork, and decals - Engine hood and panels

Hood - Replace Gas strut WARNING Crushing hazard!

Secure the hood before replacing the gas struts: 1. Support the hood with a rod.

2. Attach the handle of the hood to a crane.

Failure to comply could result in death or serious injury.

W1272A

NOTE: Gas struts are maintenance-free! They require no maintenance such as lubrication. They are designed for the respective requirements and work trouble-free for many years.

Removal 1. Use a screwdriver to lift the clips.

SVIL13COM0186AB

1

SVIL13COM0188AC

2

SVIL13COM0187AB

3

2. Pull the gas strut away from the ball joint.

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Platform, cab, bodywork, and decals - Engine hood and panels

Installing 3. The new gas struts can easily be installed by pressing them onto the ball joint.

The rod must face downward.

NOTICE: Gas struts should not be installed if they have been damaged through mechanical manipulation. – Welding on gas struts as well as dirt or paint on the piston rods can lead to failure of the units. – Avoid modifications, manipulation, impacts, tensile loading, heating, painting over or removal of imprints. – Do not install defective or improperly handled products.

NOTE: If gas struts are no longer needed, they must be disposed of in an environmentally appropriate manner. For this purpose, they will be drilled out to allow the compressed nitrogen to escape and to drain the oil they contain.

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Platform, cab, bodywork, and decals - Engine hood and panels

Hood - Depressurising CAUTION Eye injury hazard!

Always wear eye or full face protection when performing this procedure.

Failure to comply could result in minor or moderate injury.

C0081A

1. Fasten the pressurized tube between two prismatic jaws without deforming it and in such a way that the dimension (X) is at least 25 mm (1 in).

2. Slowly cut the pressurized tube open at the points indicated using a handsaw or drill a hole in the tube using a drill with about a 3 mm (0.12 in) diameter.

SS13A773

Pos. A B C D

Designation 2. Saw cut/drilled hole 1. Saw cut/drilled hole Bottom Pressurized tube

1

Pos. E X Y

Designation Piston rod at least 25 mm (1 in) about 20 mm (0.79 in)

NOTE: If disposal according to these regulations is not possible, ask your authorized dealer.

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Index Platform, cab, bodywork, and decals - 90 Engine hood and panels - 100 Hood - Depressurising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Hood - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Hood - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Hood - Replace - Hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

Hood - Replace Gas strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

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Platform, cab, bodywork, and decals - 90 Operator platform less cab - 110

DV23CC DV23 DV26CC DV26

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Contents Platform, cab, bodywork, and decals - 90 Operator platform less cab - 110

SERVICE Operator platform less cab Replace Operating lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Platform Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Platform, cab, bodywork, and decals - Operator platform less cab

Operator platform less cab - Replace Operating lever 1. Release the boot from the housing and move it upwards.

SVIL13COM0390AB

1

SVIL13COM0391AB

2

SVIL13COM0392AB

3

2. Use an Allen key to remove the screws.

3. Lift the operating lever out of the console.

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4. Disconnect connectors (S3) and (S4) .

SVIL13COM0393AB

4

SVIL13COM0394AB

5

SVIL13COM0499AB

6

SVIL13COM0500AB

7

Checking and replacing the switches 1. Use a screwdriver to pry the operating lever cap off.

Inside view of operating lever.

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Platform, cab, bodywork, and decals - Operator platform less cab

2. Use a multimeter to test the circuits continuity.

SVIL13COM0501AB

8

SVIL13COM0502AB

9

3. Remove the cables.

4. Remove the hexagon nut with a box wrench.

SVIL13COM0503AD

10

SVIL13COM0504AB

11

5. Pull out the switch.

6. Insert the new switch.

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Platform, cab, bodywork, and decals - Operator platform less cab

Platform - Remove 1. Disconnect the battery’s ground.

SVIL13COM0352AB

1

SVIL13COM0353AB

2

SVIL13COM0354AB

3

SVIL13COM0355AB

4

2. Remove the front plate from the steering column.

3. Use an Allen key to remove the steering column’s cover panel.

4. Remove the accelerator lever’s handle.

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Platform, cab, bodywork, and decals - Operator platform less cab

5. Unscrew the accelerator cable’s lock nut.

6. Uncover the accelerator cable.

SVIL13COM0356AB

5

SVIL13COM0357AB

6

SVIL13COM0358AB

7

SVIL13COM0359AB

8

7. Remove the four hydraulic hoses on the steering orbitrol.

8. Cover the fittings.

9. Disconnect the connectors on the relay panel in the steering console.

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Platform, cab, bodywork, and decals - Operator platform less cab

10. Disconnect the connectors (S1–1 and X15).

SVIL13COM0360AB

9

11. Attach the tackle to the driver’s platform: • To the seat • To the handrail NOTE: Make sure that the driver’s platform hangs horizontally.

SVIL13COM0361BB

10

SVIL13COM0362AB

11

12. Unscrew the nuts on the front rubber elements.

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Platform, cab, bodywork, and decals - Operator platform less cab

13. Remove the hexagon bolts on the back of the driver’s platform.

SVIL13COM0363AB

12

SVIL13COM0364BB

13

14. Lift the driver’s platform out from the chassis.

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Platform, cab, bodywork, and decals - Operator platform less cab

Platform - Install 1. Attach the tackle to the driver’s platform: • To the seat • To the handrail NOTE: Make sure that the driver’s platform hangs horizontally.

2. Put the driver’s platform on the chassis.

SVIL13COM0364BB

1

SVIL13COM0363AB

2

SVIL13COM0362AB

3

3. Apply LOCTITE® 242® to the hexagon bolts on the back of the driver’s platform.

4. Torque the hexagon bolts to 84 N·m (62 lb ft).

5. Apply LOCTITE® 242® to the nuts on the front rubber elements.

6. Torque the nuts to 84 N·m (62 lb ft).

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Platform, cab, bodywork, and decals - Operator platform less cab

7. Remove the tackle from the driver’s platform.

SVIL13COM0361BB

4

SVIL13COM0360AB

5

SVIL13COM0359AB

6

8. Connect the connectors (S1–1 and X15).

9. Connect the connectors on the relay panel in the steering console.

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Platform, cab, bodywork, and decals - Operator platform less cab

10. Uncover the fittings.

SVIL13COM0358AB

7

SVIL13COM0357AB

8

SVIL13COM0356AB

9

11. Install the four hydraulic hoses on the steering orbitrol.

12. Cover the accelerator cable.

13. Screw the accelerator cable’s lock nut.

14. Install the accelerator lever’s handle.

SVIL13COM0355AB

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10

Platform, cab, bodywork, and decals - Operator platform less cab

15. Use an Allen key to install the steering column’s cover panel.

16. Apply LOCTITE® 242® to the bolts.

17. Torque the bolts to 10 N·m (7 lb ft)

SVIL13COM0354AB

11

SVIL13COM0353AB

12

SVIL13COM0352AB

13

18. Install the front plate to the steering column.

19. Torque the bolts to 25.0 N·m (18.4 lb ft)

20. Connect the battery’s ground.

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Index Platform, cab, bodywork, and decals - 90 Operator platform less cab - 110 Operator platform less cab - Replace Operating lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Platform - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

Platform - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

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CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404

SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. Š 2017 CNH Industrial America LLC. All rights reserved.

No part of the text or illustrations of this publication may be reproduced.

CNH Industrial America LLC reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at the time of publication, but are subject to change without notice.

Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your CASE CONSTRUCTION dealer.

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

Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.

48142067 15/09/2017 EN

48142067 15/09/2017 EN

CNH Industrial America - Main 700 State Street Racine, Wisconsin United States 53404

SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. Š 2017 CNH Industrial America LLC. All rights reserved.

No part of the text or illustrations of this publication may be reproduced.

CNH Industrial America LLC reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at the time of publication, but are subject to change without notice.

Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your CASE CONSTRUCTION dealer.

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

Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.

48142067 15/09/2017 EN