Case DV36 DV45 Tier 4A (interim) Vibratory Roller & DV45CC Tier 4A (interim) Combination Roller SM

DV36 DV45 Tier 4A (interim) Vibratory Roller DV45CC Tier 4A (interim) Combination Roller

SERVICE MANUAL

Printed in U.S.A. © 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 48142070 1st edition English September 2017 Replaces part number 47538933

SERVICE MANUAL DV36 DV45CC DV45

48142070 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 48142070 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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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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INTRODUCTION

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

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

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

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

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

Always wear eye protection when working with batteries.

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

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

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

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

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

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

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

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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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INTRODUCTION

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, pressure plate for puller for the drive bearing flange clamp ring

SVIL13SPT0583AB

1

SVIL13SPT0584AB

2

SVIL13SPT0585AB

3

SVIL13SPT0586AB

4

Assembly tool, puller for the drive bearing flange clamp ring

Assembly tool for pendulum joint

Assembly tool for vibro shaft (1) M12 eye bolt not included in scope of delivery

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INTRODUCTION

Assembly tool, support sleeve for vibro bearing (in drive bearing flange)

SVIL13SPT0590AB

5

SVIL13SPT0595AB

6

SVIL13SPT0591AB

7

SVIL13SPT0596AB

8

Assembly tool, press-in sleeve for vibro bearing

Assembly tool for steering cylinder

Assembly tool for drive bearing

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INTRODUCTION

Assembly tool for shaft sealing ring

SVIL13SPT0597AB

9

Assembly tool for pinion fastener

SVIL13SPT0598AB

10

SVIL13SPT0601AB

11

SVIL13SPT0600AB

12

Assembly tool, pressure plate for drive bearing flange

Assembly tool, pressure plate for drive bearing flange with M16 eye bolt

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INTRODUCTION

Assembly tool, pressure plate for drive bearing flange with M16 bolt

SVIL13SPT0602AB

13

SVIL13SPT0603AB

14

SVIL13SPT0604AB

15

SVIL13SPT0605AB

16

Assembly tool for vibro shaft

Puller tool for pendulum support bolts

Special wrench for rear wheel support fastening bolts

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INTRODUCTION

Special wrench for rear wheel support fastening bolts

SVIL13SPT0606AB

17

SVIL13SPT0607AB

18

SVIL13SPT0608AB

19

SVIL13SPT0609AB

20

Special wrench for rear wheel support fastening bolts

Assembly tool, left, for SpeedySleeve ring

Assembly tool, right, for SpeedySleeve ring

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INTRODUCTION

Water tank indicator service tool

SS13A547

21

For measuring speed and frequency Tachometer

SVIL13SPT0505AB

22

SVIL13COM0061AB

23

For checking solenoids Solenoid tester

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INTRODUCTION

For checking and calibrating the pump current Connector with jumper

SS12K211

24

For Servicing Assembly tool

SVIL13SPT0589AB

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25

INTRODUCTION

For drum ballast (only for DV45) Assembly tool for lifting the roller drum ballast.

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SVIL13SPT0612AB

26

SVIL13SPT0614AB

27

INTRODUCTION

Capacities Fuel tank Capacity Specifications

59 L (15.59 US gal) #2 Diesel, ultra-low sulfur

Engine crank case oil Capacity Specifications

7.6 L (8.0 US qt) CASE AKCELA UNITEK NO. 1™ SBL CJ-4 SAE 10W-40

Hydraulic system Capacity Specifications

37.0 L (9.8 US gal) CASE AKCELA NEXPLORE™ FLUID

Coolant — CNH XHD HEAVY DUTY COOLANT / ANTI-FREEZE

Capacity Specifications

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

Quantity Specifications

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

Quantity Specifications

Water Tank Quantity Specifications

350 L (92.46 US gal) Water

Emulsion tank (DV45CC) Quantity

18 L (5 US gal)

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INTRODUCTION

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 DV36 DV45CC DV45

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Contents Maintenance - 00

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

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Maintenance - 00 Start-up - 150

DV36 DV45CC DV45

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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 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 Vibration switching valve Y5, Y6, Y7, Y8

Correction • Check the connectors on the magnetic 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. © 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 Engine DV36 DV45CC DV45

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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

DV36 DV45CC DV45

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Contents Engine - 10 Engine and crankcase - 001

SERVICE Engine Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

DIAGNOSTIC Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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

SVIL13COM0520AB

1

SVIL13COM0498AB

2

SVIL13COM0058AB

3

SVIL13COM0057AB

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.

NOTE: Source the tachometer locally.

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

6. Tighten the nuts.

7. Check the fastening (2) on the ball head.

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Engine - Engine and crankcase

Engine RPM Engine RPM, 100% Simple vibration speed, front Double vibration, front Double vibration, rear Double vibration, low frequency / small amplitude front Double vibration, low frequency / small amplitude rear Double vibration, low frequency / large amplitude front Double vibration, low frequency / large amplitude rear Engine RPM under load (driving and double vibration)

At the beginning 2410 – 2450 RPM 3230 – 3330 RPM 3000 – 3300 RPM 2650 – 2950 RPM 2500 – 2800 RPM

After 60 min 2360 – 2400 RPM 3230 – 3330 RPM 3000 – 3300 RPM 2650 – 2950 RPM 2430 – 2730 RPM

Hz

1900 – 2200 RPM

1900 – 2200 RPM

34

2050 – 2350 RPM

2200 – 2500 RPM

39

2500 – 2800 RPM

2430 – 2730 RPM

43

2385 – 2435 RPM

2345 – 2395 RPM

54 52 46 43

Pressures At the beginning 70 – 110 bar (1015 – 1595 psi) 50 – 90 bar (725 – 1305 psi)

Pressures during MA and MB driving operation Pressures for vibratory operation, front Pressures for vibratory operation, front and rear Double vibration, low frequency / small amplitude Double vibration, low frequency / large amplitude

After 60 min 70 – 110 bar (1015 – 1595 psi) 37 – 53 bar (536 – 768 psi) 110 – 170 bar (1595 – 65 – 85 bar (942 – 2465 psi) 1232 psi) 52 – 68 bar (754 – 986 psi) 57 – 73 bar (826 – 1058 psi)

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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.

RAIL13SSL0079BA

1

RAIL13SSL0159BA

2

RAIL13SSL0158BA

3

6. Disconnect the intake snorkel (1).

7. Disconnect the air box snorkel (2).

8. Remove the air box.

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Engine - Engine and crankcase

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

10. Disconnect the glow plug wire (2).

RAIL13SSL0161BA

4

RAIL13SSL0160BA

5

RAIL13SSL0170BA

6

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

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

13. Disconnect the throttle cable (2) from the injection pump.

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Engine - Engine and crankcase

14. Disconnect the wire (1) for the oil pressure sender.

15. Disconnect the electrical connector (2) for the fuel pump.

16. Disconnect and cap the drain hose (3) for the oil pan.

17. Disconnect and cap the fuel feed hose (4).

RAIL13SSL0169BA

7

RAIL13SSL0164BA

8

RAIL13SSL0156BA

9

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

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

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Engine - Engine and crankcase

20. Remove the U-bolt (1).

RAIL13SSL0163BA

10

RAIL13SSL0157BA

11

RAIL13SSL0172BA

12

21. Disconnect and remove the muffler.

22. Disconnect the negative battery cable (1) and the positive battery cable (2).

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Engine - Engine and crankcase

23. Remove the battery hold-down assembly (1).

24. Remove the battery.

RAIL13SSL0173BA

13

RAIL13SSL0171BA

14

RAIL13SSL0162BA

15

25. Remove the battery tray hardware (1).

26. Remove the battery tray.

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

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

29. Disconnect the battery cable (3) on the starter.

30. Disconnect the starter ignition wire (4).

31. Disconnect the ground cable (5).

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Engine - Engine and crankcase

32. Install a suitable lifting device (1) to the pump assembly.

RAIL13SSL0168BA

16

RAIL13SSL0167BA

17

RAIL13SSL0166BA

18

33. Remove the bell housing bolts.

34. Remove the engine mount bolts.

35. Repeat step 34 on the other side.

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Engine - Engine and crankcase

36. Attach a suitable lifting device to the engine, and remove the engine.

RAIL13SSL0165BA

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19

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.

RAIL13SSL0165BA

1

RAIL13SSL0166BA

2

RAIL13SSL0167BA

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 pump assembly.

RAIL13SSL0168BA

4

RAIL13SSL0162BA

5

RAIL13SSL0171BA

6

6. Connect the battery wire (1) on the alternator.

7. Connect the regulator connector (2) on the alternator.

8. Connect the battery cable (3) on the starter.

9. Connect the starter ignition wire (4).

10. Connect the ground cable (5).

11. Install the battery tray and hardware (1).

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Engine - Engine and crankcase

12. Install the battery and hold-down assembly (1).

RAIL13SSL0173BA

7

RAIL13SSL0172BA

8

RAIL13SSL0157BA

9

13. Connect the negative battery cable (1) and the positive battery cable (2).

14. Install the muffler.

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Engine - Engine and crankcase

15. Install the U-bolt (1).

RAIL13SSL0163BA

10

RAIL13SSL0156BA

11

RAIL13SSL0164BA

12

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

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

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Engine - Engine and crankcase

18. Connect the wire (1) for the oil pressure sender.

19. Connect the electrical connector (2) for the fuel pump.

20. Connect the drain hose (3) for the oil pan.

21. Connect the fuel feed hose (4).

RAIL13SSL0169BA

13

RAIL13SSL0170BA

14

RAIL13SSL0161BA

15

22. Connect the throttle cable (2) to the injection pump.

23. 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)

24. Connect the glow plug wire (2).

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

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Engine - Engine and crankcase

26. Install the P-clamps (1) that retain the engine harness.

RAIL13SSL0160BA

16

RAIL13SSL0158BA

17

RAIL13SSL0159BA

18

27. Install the air box.

28. Connect the intake snorkel (1).

29. Connect the air box snorkel (2).

30. Carefully lower the hood into position.

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Engine - Engine and crankcase

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

32. Connect the hood strut (2).

33. Connect the lamps (1).

34. Repeat steps 31 – 33 on the opposite side.

RAIL13SSL0079BA

35. Remove the lifting equipment from the hood.

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19

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

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

6

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

3

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

20

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Engine - 10 Engine cooling system - 400

DV36 DV45CC DV45

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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. © 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.

48142070 15/09/2017 EN

SERVICE MANUAL Hydrostatic drive DV36 DV45CC DV45

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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

DV36 DV45CC DV45

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Contents Hydrostatic drive - 29 Pump and motor components - 218

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

FUNCTIONAL DATA Motor Travel motor - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Pump Hydrostatic circuit supply pump - Check the supply pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Check the drive pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Adjust the neutral position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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

Motor Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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Hydrostatic drive - Pump and motor components

Pump - General specification

RAIL13COM0022FA

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) 425 – 455 bar (6162 – 6598 psi) 425 – 455 bar (6162 – 6598 psi)

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Travel motor - Component identification DV36

SS13A498

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 22 23

Designation Wheel support Hose guide Spacer plate Spacer plate Strain washer Hexagon nut Bearing support Grooved ball bearing Clamp ring Shaft seal ring Wheel Wheel support Hexagon head screw Clamp Lock washer Socket head cap screw Hexagon head screw Wheel disk Spacer Hexagon nut Rubber cushion Hexagon head screw Strain washer

Pos. 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

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Designation Cover Bearing flange Strain washer X-ring Washer Hexagon head screw Hexagon nut Strain washer Coupling sleeve Hub Clamp Male stud coupling body Male stud coupling body Male stud coupling body Fluid motor Male stud coupling body Gear motor Socket head cap screw O-ring Angle flange connection O-ring Angle flange connection

Hydrostatic drive - Pump and motor components

DV45

SS13A499

2

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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 22 23

Designation Wheel support Hose guide Spacer plate Spacer plate Strain washer Hexagon nut Bearing support Grooved ball bearing Clamp ring Shaft seal ring Wheel Wheel support Hexagon head screw Clamp Lock washer Socket head cap screw Hexagon head screw Wheel disk Spacer Hexagon nut Rubber cushion Hexagon head screw Strain washer

Pos. 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

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Designation Cover Bearing flange Strain washer X-ring Washer Hexagon head screw Hexagon nut Strain washer Coupling sleeve Hub Clamp Male stud coupling body Male stud coupling body Male stud coupling body Fluid motor Male stud coupling body Gear motor Socket head cap screw O-ring Angle flange connection O-ring Angle flange connection

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.

SVIL13COM0496AB

1

SVIL13COM0497AB

2

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

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

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

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Pump - Check the drive pressure 1. Disconnect the forward (MB) contact lines.

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

SVIL13COM0512AB

1

SVIL13COM0513AB

2

SVIL13COM0514AB

3

3. Disconnect the backward (MA) contact lines.

4. Seal the lines in such a way that pressure will not force them back open.

5. Connect the 450 bar (6525 psi) measuring device to the measuring points MA and MB. 6. Start the engine and set it to maximum speed.

7. Move the operating lever all the way forward.

Reading: 425 – 455 bar (6162 – 6598 psi) 8. Move the operating lever all the way back.

Reading: 425 – 455 bar (6162 – 6598 psi) NOTICE: Oil can overheat and seals can be damaged.

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

5 s.

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

10. Start a test run.

11. Check whether the connections are leak-tight.

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Hydrostatic drive - Pump and motor components

Pump - Adjust the neutral position 1. Remove the (X1) and (X2) plugs.

SVIL13COM0341AB

1

SVIL13COM0342AB

2

SVIL13COM0343AB

3

SVIL13COM0365AB

4

2. Use an Allen key to remove the cap.

3. Check the cap (1) for any dirt accretions or other blockages.

Use compressed air to clean them out.

NOTE: The cap must be tightened securely when reassembled!

4. Jack up the machine safely.

5. Let the machine run.

6. Unscrew the lock screw (1).

7. Set the neutral position (2).

Turn the key carefully until the roller drum stops.

8. Tighten the lock screw.

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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.

SVIL13COM0496AB

1

SVIL13COM0497AB

2

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

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

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

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Hydrostatic drive - Pump and motor components

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

SVIL13COM0382AB

1

SVIL13COM0379AB

2

SVIL13COM0380AB

3

SVIL13COM0381AB

4

2. Remove the hydraulic hoses from the drive motor.

3. Plug the fittings.

4. Relieve the pressure on the rubber elements.

A. Use a crane to slightly lift the roller.

B. Place a spacer plate ( 40 mm (1.6 in) thick) between the roller drum and the chassis.

5. Lower the chassis.

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Hydrostatic drive - Pump and motor components

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

7.

SVIL13COM0548AB

5

SVIL13COM0383AB

6

SVIL13COM0384AB

7

SVIL13COM0523AB

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.

8. Remove the floor panel.

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

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

NOTE: The bolts will go through. Make sure to follow the step 2.

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Hydrostatic drive - Pump and motor components

11. Make a tool (1) to hold the inside nuts (3) in place while removing the bolts (2) from the outside. If this is not possible remove the water tank for easier access to the nuts.

NOTE: The dealer made tool (1) shown is a box end wrench with a extension bar welded to the end of it.

SVIL13COM0522AB

12. Remove the sling.

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9

SVIL13COM0521AB

10

SVIL13COM0634AB

11

SVIL13COM0524AB

12

Hydrostatic drive - Pump and motor components

13. Remove the spacer plate.

SVIL13COM0525AB

13

SVIL13COM0526AB

14

SVIL13COM0532AB

15

SVIL13COM0533AB

16

14. Attach the sling again.

15. Remove the lower bolts on the wheel support.

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

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Hydrostatic drive - Pump and motor components

17.

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 hexagon nuts

SVIL13COM0534AB

17

SVIL13COM0535AB

18

SVIL13COM0314AB

19

SVIL13COM0316AB

20

18. Use the crane to lift the wheel support away from the roller drum.

Removing the drive motor 1. Remove the hexagon nuts on the wheel disk.

2. Remove the wheel disk.

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Hydrostatic drive - Pump and motor components

3. Remove the spacer.

SVIL13COM0315AB

21

SVIL13COM0547AB

22

SVIL13COM0318AB

23

4. Remove the male nipples.

5. Cover the threads.

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6. Remove the hexagon bolts.

SVIL13COM0319AB

24

SVIL13COM0320AB

25

SVIL13COM0321AB

26

SVIL13COM0322AB

27

7. Mount the lifting device on the drive motor.

8. Lift the drive motor out of support.

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Hydrostatic drive - Pump and motor components

Motor - Install Installing a new drive motor 1. Clean the wheel support.

2. Grease the drive motor’s seat.

SVIL13COM0323AB

1

SVIL13COM0322AB

2

SVIL13COM0319AB

3

SVIL13COM0318AB

4

3. Insert the new drive motor.

4. Apply LOCTITE® 242® to the hexagon bolts and torque them to 210 N·m (155 lb ft).

5. Remove the plugs.

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Hydrostatic drive - Pump and motor components

6. Apply LOCTITE® 242® to the male nipples: Two 20S/R3/4 male nipples (1) One 12L/R3/8 male nipple (2) One 10L/R1/4 male nipple (3)

SVIL13COM0324AB

5

SVIL13COM0325AB

6

SVIL13COM0315AB

7

SVIL13COM0317AB

8

7. Install the male nipples.

20S = tightening torque of 170 N·m (125.4 lb ft) 12L = tightening torque of 55 N·m (40.6 lb ft) 10L = tightening torque of 45 N·m (33.2 lb ft) 8. Cover the fittings.

9. Install the spacer.

10. Apply LOCTITE® 242® to the bolts.

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Hydrostatic drive - Pump and motor components

11. Place the wheel disk on the motor.

SVIL13COM0316AB

9

12. Torque the wheel disk to 195 N·m (143.8 lb ft).

SVIL13COM0314AB

10

SVIL13COM0535AB

11

SVIL13COM0534AB

12

13. Release the brakes and align the wheel disk.

14. Assemble the entire wheel support back onto the roller drum.

15. Torque the hexagon nuts and spring washers to 210 N·m (155 lb ft).

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16. Apply LOCTITE® 242® to the lower bolts on the wheel support.

17. Install the lower bolts.

SVIL13COM0532AB

13

SVIL13COM0526AB

14

SVIL13COM0525AB

15

18. Install the weights.

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Hydrostatic drive - Pump and motor components

19. Make a tool (1) to hold the inside nuts (3) in place while installing the bolts (2) from the outside. If this is not possible remove the water tank for easier access to the nuts.

NOTE: The dealer made tool (1) shown is a box end wrench with a extension bar welded to the end of it.

20. Apply LOCTITE® 242® to the upper wheel support bolts and install them.

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SVIL13COM0634AB

16

SVIL13COM0521AB

17

SVIL13COM0522AB

18

SVIL13COM0524AB

19

Hydrostatic drive - Pump and motor components

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

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

SVIL13COM0523AB

20

SVIL13COM0384AB

21

SVIL13COM0383AB

22

SVIL13COM0548AC

23

23. Apply LOCTITE® 242® to the bolts.

24. Install the floor panel.

25. Torque the bolts to 25.0 N·m (18.4 lb ft).

26. Remove the brake-releasing plate.

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

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Hydrostatic drive - Pump and motor components

28. Relieve the pressure on the rubber elements.

• Use a crane to slightly lift the roller.

29. Remove the spacer plate.

30. Lower the chassis.

SVIL13COM0380AB

24

SVIL13COM0381AB

25

SVIL13COM0379AB

26

31. Unplug the fittings.

32. Install the hydraulic hoses from the drive motor.

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Index Hydrostatic drive - 29 Pump and motor components - 218 Hydrostatic circuit supply pump - Check the supply pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

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

8

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

19

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

12

Pump - Adjust the neutral position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

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

9

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

3

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

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. © 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.

48142070 15/09/2017 EN

SERVICE MANUAL Brakes and controls DV36 DV45CC DV45

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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

DV36 DV45CC DV45

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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

SS13A896

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

DV36 DV45CC DV45

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

SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 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.

48142070 15/09/2017 EN

SERVICE MANUAL Hydraulic systems DV36 DV45CC DV45

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35

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

DV36 DV45CC DV45

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

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Hydraulic systems - Fixed displacement pump

Pump - General specification

RAIL13COM0022FA

1

Tandem pump Callout (1) (2)

Location M2, vibro pressure M3, steering pressure

Pressure 240 – 260 bar (3480 – 3770 psi) (double vibration) 170 – 190 bar (2465 – 2755 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

DV36 DV45CC DV45

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

SERVICE Hydraulic systems Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 (TL) • (23) = Brake valve (A1.1)

SVIL13COM0335AB

1

SVIL13COM0337AB

2

SVIL13COM0338AB

3

SVIL13COM0336AB

4

Hydraulic hoses on the front roller drum • (24) = Vibro switch valve (A) • (25) = Vibro switch valve (B1) • (26) = Vibro switch valve (TL)

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 (B1) • (35) = Vibro switch valve (C) • (36) = Oil cooler

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Hydraulic systems - Hydraulic schema DV36 DV45

SVIL13COM0651HB

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 DV45CC

RAIL17COM0026HA

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. 450 bar (6525 psi) For supply pressure = min. 40 bar (580 psi)

SVIL13COM0333AC

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 425 – 455 bar (6162 – 6598 psi); measure with the roller drums blocked.

MB forward drive pressure of 425 – 455 bar (6162 – 6598 psi); measure with the roller drums blocked.

M2 vibro pressure of 240 – 260 bar (3480 – 3770 psi) (double vibration).

M3 steering pressure (this measuring connection is installed). 170 – 190 bar (2465 – 2755 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.

SVIL13COM0334AC

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 170 – 190 bar (2465 – 2755 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 - Hydraulic systems

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

SVIL13COM0463AB

1

SVIL13COM0462AC

2

SVIL13COM0470AB

3

SVIL13COM0471AB

4

Example of pressure regulating valve soiling.

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

1. Remove the valve plugs with an Allen key.

• (5.1) = Vibration, front • (5.2) = Vibration, rear NOTE: The torque when reinstalling is 90 N·m (66.38 lb ft).

2. Remove the inner securing ring.

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3. Take the whole valve assembly out from the block with ring opening pliers.

SVIL13COM0472AB

5

SVIL13COM0454AB

6

SVIL13COM0456AB

7

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

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

SVIL13COM0473EB

8

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

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Pos. 1 2 3 4 5

Designation

Pos. 6 7 8 9

Cover screw Short spring Valve head Valve seat Long spring

Designation Plunger O-ring Cylinder Inner securing ring

7. Mount the valve seat.

8. Insert the long spring.

SVIL13COM0474AB

9

9. Assemble the cylinder and the plunger together.

SVIL13COM0475AB

10

SVIL13COM0476AB

11

10. Grab the complete cylinder with ring opening pliers.

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11. Push the complete cylinder (1) into the hole all the way to the stop.

SVIL13COM0478AB

12

SVIL13COM0480AB

13

SVIL13COM0482AB

14

SVIL13COM0483AB

15

12. Insert the inner securing ring.

13. Assemble the cover screw, short spring, and valve head together.

14. Insert the complete cover screw and torque it to 125 N·m (92.20 lb ft).

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Magnetic coils 1. All solenoids can be actuated manually.

SVIL13COM0464AB

16

SVIL13COM0465AB

17

SVIL13COM0466AB

18

SVIL13COM0484AB

19

Solenoid designations • (Y5) = Vibration, front • (Y6) = Vibration, rear • (Y7) = Large amplitude • (Y8) = Low frequency

2. Measure the solenoid’s resistance.

The value should be 6 Ω.

3. Remove the solenoid.

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4. Unscrew the solenoid valve.

NOTE: Make sure to apply a torque of 40 N·m (29.50 lb ft) when reinstalling.

SVIL13COM0485AB

20

SVIL13COM0467AB

21

SVIL13COM0468AB

22

SVIL13COM0376AB

23

5. Measure the solenoid’s resistance.

• (Y7) = 5 Ω • (Y5)/ (Y6)/ (Y8) = 6 Ω

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

7. The valve must be visibly and audibly actuated.

8. Check the gaskets (1) for damage.

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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

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Hydraulic systems - 35 Pump control valves - 102

DV36 DV45CC DV45

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Contents Hydraulic systems - 35 Pump control valves - 102

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

DIAGNOSTIC Flow divider Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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

SVIL13COM0301AB

1

SVIL13COM0302AB

2

SVIL13COM0303AB

3

SVIL13COM0304AB

4

2. Measure the solenoid’s resistance.

The value should be 6 Ω.

3. Remove the plunger assembly.

4. Unscrew the cover screws on both sides.

5. Spring assembly (1).

6. Check the plunger (2) for damage.

7. Check the housing for soiling.

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

9. Oil the plunger before reassembly.

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

11. The plunger must not seize in any position.

SVIL13COM0305AB

5

SVIL13COM0307AB

6

12. 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).

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

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Hydraulic systems - 35 Hydraulic travel system - 353

DV36 DV45CC DV45

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SERVICE Travel motor Remove Wheel - support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install Wheel - support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Remove - Rear drive motor (DV45CC) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install - Rear drive motor (DV45CC) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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Hydraulic systems - Hydraulic travel system

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

SVIL13COM0382AB

1

SVIL13COM0379AB

2

SVIL13COM0380AB

3

SVIL13COM0381AB

4

2. Remove the hydraulic hoses from the drive motor.

3. Plug the fittings.

4. Relieve the pressure on the rubber elements.

A. Use a crane to slightly lift the roller.

B. Place a spacer plate ( 40 mm (1.6 in) thick) between the roller drum and the chassis.

5. Lower the chassis.

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

7.

SVIL13COM0548AB

5

SVIL13COM0383AB

6

SVIL13COM0384AB

7

SVIL13COM0523AB

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.

8. Remove the floor panel.

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

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

NOTE: The bolts will go through. Make sure to follow the step 11.

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11. Make a tool (1) to hold the inside nuts (3) in place while removing the bolts (2) from the outside. If this is not possible remove the water tank for easier access to the nuts.

NOTE: The dealer made tool (1) shown is a box end wrench with a extension bar welded to the end of it.

SVIL13COM0522AB

12. Remove the sling.

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9

SVIL13COM0521AB

10

SVIL13COM0634AB

11

SVIL13COM0524AB

12

Hydraulic systems - Hydraulic travel system

13. Remove the spacer plate.

SVIL13COM0525AB

13

SVIL13COM0526AB

14

SVIL13COM0532AB

15

SVIL13COM0533AB

16

14. Attach the sling again.

15. Remove the lower bolts on the wheel support.

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

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17.

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 hexagon nuts

SVIL13COM0534AB

17

SVIL13COM0535AB

18

18. Use the crane to lift the wheel support 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.

SVIL13COM0535AB

1

SVIL13COM0534AB

2

SVIL13COM0532AB

3

2. Apply LOCTITE® 242® to the hexagon nuts.

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

4. Apply LOCTITE® 242® to the lower bolts on the wheel support.

5. Install the lower bolts.

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6. Install the weights.

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SVIL13COM0526AB

4

SVIL13COM0525AB

5

Hydraulic systems - Hydraulic travel system

7. Make a tool (1) to hold the inside nuts (3) in place while installing the bolts (2) from the outside. If this is not possible remove the water tank for easier access to the nuts.

NOTE: The dealer made tool (1) shown is a box end wrench with a extension bar welded to the end of it.

8. Apply LOCTITE® 242® to the upper wheel support bolts and install them.

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SVIL13COM0634AB

6

SVIL13COM0521AB

7

SVIL13COM0522AB

8

SVIL13COM0524AB

9

Hydraulic systems - Hydraulic travel system

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).

SVIL13COM0523AB

10

SVIL13COM0384AB

11

SVIL13COM0383AB

12

SVIL13COM0548AC

13

11. Apply LOCTITE® 242® to the bolts.

12. Install the floor panel.

13. Torque the bolts to 25.0 N·m (18.4 lb ft).

14. Remove the brake-releasing plate.

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

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16. Relieve the pressure on the rubber elements.

• Use a crane to slightly lift the roller.

17. Remove the spacer plate.

18. Lower the chassis.

SVIL13COM0380AB

14

SVIL13COM0381AB

15

SVIL13COM0379AB

16

19. Unplug the fittings.

20. Install the hydraulic hoses from the drive motor.

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Travel motor - Remove - Rear drive motor (DV45CC) DV45CC

1. Raise the unit off the ground and properly support the unit with jack stands.

2. Remove the inner wheel valve from the guide.

NOTICE: Failure to remove the inner valve from the guide could cause the valve to be broken off during wheel removal.

RAIL17COM0019AA

1

RAIL17COM0018AA

2

RAIL17COM0020AA

3

3. Properly support both inner and outer wheel.

4. Remove the six M22 wheel retaining nuts and split washers.

5. Remove both wheels from the unit.

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6. Remove and cap all lines to the drive motor.

7. Disconnect the hoses on the opposite drive motor so that they can be moved out of the way.

RAIL17COM0021AA

4

RAIL17COM0022AA

5

RAIL17COM0023AA

6

8. Remove and cap the fittings from the drive motor.

9. Remove the six M12 bolts retaining the drive motor.

10. Remove the drive motor from the unit.

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Travel motor - Install - Rear drive motor (DV45CC) DV45CC

1. Apply LOCTITE® 221 thread locker to the six M12 drive motor bolts.

RAIL17COM0014AA

1

RAIL17COM0024AA

2

RAIL17COM0025AA

3

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

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

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

5. Torque the fittings as follows: (1) to 135 N·m (100 lb ft) (2) to 55 N·m (41 lb ft) (3) to 45 N·m (33 lb ft).

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

RAIL17COM0021AA

4

RAIL17COM0016AA

5

RAIL17COM0020AA

6

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

8. Reinstall the wheels and torque the nuts to 195 N·m (144 lb ft).

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9. Reconnect the inner wheel valve to the guide.

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

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

RAIL17COM0019AA

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7

Index Hydraulic systems - 35 Hydraulic travel system - 353 Travel motor - Install - Rear drive motor (DV45CC) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

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

8

Travel motor - Remove - Rear drive motor (DV45CC) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

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

3

(*) See content for specific models 48142070 15/09/2017

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

DV36 DV45CC DV45

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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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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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DV36 DV45CC DV45

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

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

Compaction/vibration motor Remove Wheel - support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install Wheel - support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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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 - Disassemble 1. Remove the valve plugs with an Allen key.

• (5.1) = Vibration, front • (5.2) = Vibration, rear

SVIL13COM0470AB

1

SVIL13COM0471AB

2

SVIL13COM0472AB

3

2. Remove the inner securing ring.

3. Take the whole valve assembly out from the block with ring opening pliers.

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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

SVIL13COM0536AB

3

3. Remove the upper bolts on the vibromotor side.

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4. Loosen the lower bolts.

5.

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

Lift out the weight.

SVIL13COM0537AB

4

SVIL13COM0539AB

5

SVIL13COM0540AB

6

SVIL13COM0548AB

7

6. Remove the hose strap.

7. Disconnect the hydraulic hoses and plug them.

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

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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.

SVIL13COM0549AB

8

SVIL13COM0541AB

9

10. Remove the lower bolts.

11. Remove the hexagon nuts.

12. Remove the wheel support.

SVIL13COM0576AB

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Hydraulic systems - Compaction/vibration hydraulic system

Compaction/vibration motor - Install Wheel - support 1. Install the wheel support.

2. Apply LOCTITE® 242® to the hexagon nuts.

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

SVIL13COM0576AB

1

SVIL13COM0540AB

2

SVIL13COM0539AB

3

SVIL13COM0541AB

4

4. Connect the hydraulic hoses.

5. Apply LOCTITE® 242® to the bolts.

6. Install the hose strap and torque the screws to 10.0 N·m (7.4 lb ft).

7. Apply LOCTITE® 242® to the lower bolts.

8. Install the lower bolts.

9. Install the weights.

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10. Remove the brake-releasing plate.

SVIL13COM0549AB

5

SVIL13COM0548AC

6

SVIL13COM0536AB

7

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

12. Apply LOCTITE® 242® to the upper wheel support bolts.

13. Install the upper wheel support bolts.

14. Torque the lower bolts to 306 N·m (226 lb ft).

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

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16. Relieve the pressure on the rubber elements.

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

17. Remove the spacer plate.

18. Lower the chassis.

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SVIL13COM0408BB

8

SVIL13COM0396AB

9

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

3

Compaction/vibration hydraulic system - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

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

9

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

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. © 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.

48142070 15/09/2017 EN

SERVICE MANUAL Frames and ballasting DV36 DV45CC DV45

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Contents Frames and ballasting - 39

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

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Frames and ballasting - 39 Frame - 100

DV36 DV45CC DV45

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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

SS13A780

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

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Designation Hexagon head screw Strain washer 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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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 6 mm (0.24 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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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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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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Frames and ballasting - Frame

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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Frames and ballasting - Frame

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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Frames and ballasting - Frame

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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Frames and ballasting - Frame

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. © 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.

48142070 15/09/2017 EN

SERVICE MANUAL Steering DV36 DV45CC DV45

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41

Contents Steering - 41

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

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Steering - 41 Steering control - 101

DV36 DV45CC DV45

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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. © 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.

48142070 15/09/2017 EN

SERVICE MANUAL Wheels DV36 DV45CC DV45

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44

Contents Wheels - 44

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

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Wheels - 44 Compaction drums - 160

DV36 DV45CC DV45

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Contents Wheels - 44 Compaction drums - 160

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

Compaction front drum shaft Compaction drums - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Compaction rear drum shaft Compaction drums - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Compaction drums Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Remove the drum ballasts (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Install the drum ballasts (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Disassemble Drive - bearing - flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Assemble Drive - bearing - flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Disassemble Vibro - bearing - flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Assemble Vibro - bearing - flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Replace the rubber element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Compaction front drum shaft Compaction rear drum shaft - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Compaction rear drum shaft - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Compaction rear drum shaft Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

(*) See content for specific models 48142070 15/09/2017

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Wheels - Compaction drums

Compaction drums - Component identification - drum ballasts

SVIL13COM0631FB

Pos. 90 91

Designation Ballast plate Bushing

1

Pos. 92 93

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Designation Hexagon head screw Washer

Wheels - Compaction drums

Compaction drums - Component identification

SS13A497

1

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Wheels - Compaction drums

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

Designation Countersunk screw Plate spring Hub Hexagon nut Bushing Shoulder bolt Vibrating shaft Feather key Unbalance flywheel Feather key Threaded rod with drilled hole Bearing bushing

Pos. 13 14 15 16 17 18 19 20 21 22 23 24

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Designation Unbalance flywheel Circlip Shaft protection sleeve Shaft seal ring Circlip Spherical roller bearing Liquid grease Bearing housing Sealing ring Screw plug Socket head cap screw Strain washer

Wheels - Compaction drums

Compaction drums - Component identification

SS13A497

1

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Wheels - Compaction drums

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

Designation Countersunk screw Plate spring Hub Hexagon nut Bushing Shoulder bolt Vibrating shaft Feather key Unbalance flywheel Feather key Threaded rod with drilled hole Bearing bushing

Pos. 13 14 15 16 17 18 19 20 21 22 23 24

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Designation Unbalance flywheel Circlip Shaft protection sleeve Shaft seal ring Circlip Spherical roller bearing Liquid grease Bearing housing Sealing ring Screw plug Socket head cap screw Strain washer

Wheels - Compaction drums

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

1. Engage the articulation joint support bar.

SVIL13COM0409AB

1

SVIL13COM0398AB

2

SVIL13COM0382AB

3

2. Secure the machine with wheel chocks.

Drive motor side 1. Remove the hose bracket.

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Wheels - Compaction drums

2. Remove the hydraulic hoses from the drive motor.

3. Plug the fittings.

SVIL13COM0379AB

4

SVIL13COM0380AB

5

SVIL13COM0381AB

6

SVIL13COM0548AB

7

4. Relieve the pressure on the rubber elements.

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

B. Place a spacer plate ( 40 mm (1.6 in) thick) between the roller drum and the chassis.

5. Lower the chassis.

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

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Wheels - Compaction drums

7.

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.

SVIL13COM0383AB

8

SVIL13COM0384AB

9

8. Remove the floor panel.

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

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

NOTE: The bolts will go through. Make sure to follow the step 11 and release the brakes!

SVIL13COM0523AB

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10

Wheels - Compaction drums

11. Make a tool (1) to hold the inside nuts (3) in place while removing the bolts (2) from the outside. If this is not possible remove the water tank for easier access to the nuts.

NOTE: The dealer made tool (1) shown is a box end wrench with a extension bar welded to the end of it.

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SVIL13COM0521AB

11

SVIL13COM0522AB

12

SVIL13COM0634AB

13

SVIL13COM0524AB

14

Wheels - Compaction drums

12. Remove the sling.

13. Remove the spacer plate.

SVIL13COM0525AB

15

SVIL13COM0526AB

16

SVIL13COM0532AB

17

SVIL13COM0536AB

18

14. Attach the sling again.

15. Remove the lower bolts on the wheel support.

Vibro-motor side 1. Remove the upper bolts on the vibro-motor side.

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2. Loosen the lower bolts.

3. Lift out the weight.

SVIL13COM0537AB

19

SVIL13COM0539AB

20

SVIL13COM0540AB

21

SVIL13COM0538AC

22

4. Remove the hose strap.

5. Disconnect the hydraulic hoses and plug the ends.

6. Attach the crane sling to the wheel support.

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Wheels - Compaction drums

7.

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.

SVIL13COM0541AB

23

SVIL13COM0542AB

24

SVIL13COM0543AB

25

8. Carefully lower the support with the crane.

NOTICE: Guide the hydraulic hoses with your hand so that they are not damaged.

9. Carefully lower the wheel supports onto the floor.

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10. Use the crane to lift the chassis.

SVIL13COM0544BB

26

SVIL13COM0545AB

27

SVIL13COM0546AB

28

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

12. Remove the roller drum by pulling it backwards.

13. Place the lower part of the chassis on the support.

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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 the crane to lift the machine.

2. Position the roller drum.

3. Secure the roller drum with wheel chocks.

SVIL13COM0405AB

1

SVIL13COM0381AB

2

SVIL13COM0549AB

3

4. Place a spacer plate 40 mm (1.6 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 on the drive motor side and release the brakes. Refer to Parking brake or parking lock - Service instruction Release the Brakes (33.110).

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Wheels - Compaction drums

Vibro-motor side 1. Attach the crane sling to the wheel support and bring it in to the mounting position.

NOTICE: Guide the hydraulic hoses with your hand so that they are not damaged.

SVIL13COM0538AC

4

SVIL13COM0541AB

5

SVIL13COM0537AB

6

SVIL13COM0536AB

7

2. Apply LOCTITE® 242® to the lower bolts.

3. Install the lower bolts.

4. Lift in the weight.

5. Torque the lower bolts to 306 N·m (226 lb ft).

6. Apply LOCTITE® 242® to the upper bolts.

7. Install the upper bolts and torque them to 306 N·m (226 lb ft).

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8. Connect the hydraulic hoses.

SVIL13COM0540AB

8

SVIL13COM0539AB

9

9. Install the hose strap.

Drive motor side 1. Attach the crane sling to the wheel support and bring it in the mounting position.

2. Install the lower bolts on the wheel support.

SVIL13COM0532AB

3. Remove the sling.

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10

Wheels - Compaction drums

4. Install the weight.

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SVIL13COM0526AB

11

SVIL13COM0525AB

12

Wheels - Compaction drums

5. Make a tool (1) to hold the inside nuts (3) in place while installing the bolts (2) from the outside. If this is not possible remove the water tank for easier access to the nuts.

NOTE: The dealer made tool (1) shown is a box end wrench with a extension bar welded to the end of it.

6. Apply LOCTITE® 242® to the upper wheel support bolts and install them.

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SVIL13COM0634AB

13

SVIL13COM0521AB

14

SVIL13COM0522AB

15

SVIL13COM0524AB

16

Wheels - Compaction drums

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

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

SVIL13COM0523AB

17

SVIL13COM0384AB

18

SVIL13COM0383AB

19

SVIL13COM0548AC

20

9. Apply LOCTITE® 242® to the bolts.

10. Install the floor panel.

11. Torque the bolts to 25.0 N·m (18.4 lb ft)

12. Remove the brake-releasing plate.

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

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Wheels - Compaction drums

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 machine

SVIL13COM0381AB

21

SVIL13COM0379AB

22

SVIL13COM0382AB

23

SVIL13COM0398AB

24

17. Remove the fittings.

18. Install the hydraulic hoses from the drive motor.

19. Apply LOCTITE® 242® to the bolts.

20. Install the hose bracket.

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

22. Remove the wheel chocks.

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23. Remove the joint protection.

SVIL13COM0409AB

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Compaction drums - Remove the drum ballasts DV45CC DV45

Tools that can be used in order to install roller drum ballasts.

SVIL13SPT0612AB

1

SVIL13SPT0614AB

2

SVIL13COM0527AB

3

SVIL13COM0528AC

4

1. Position the lift truck under the roller drum ballast.

2. Lift slightly.

3. Remove the hexagon bolts.

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4. Pull out the roller drum ballast.

SVIL13COM0529AB

5

SVIL13COM0531AC

6

5. Safely put down the roller drum ballast.

NOTE: The procedure on the vibromotor side is the same.

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Compaction drums - Install the drum ballasts DV45CC DV45

Tools that can be used in order to install roller drum ballasts.

SVIL13SPT0612AB

1

SVIL13SPT0614AB

2

SVIL13COM0531AC

3

SVIL13COM0529AC

4

1. Lift up the ballast with the lift truck.

2. Put in the roller drum ballast.

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

4. Torque the hexagon bolts to 210 N·m (154.9 lb ft).

SVIL13COM0528AC

5. Remove the lift truck.

NOTE: The procedure on the vibromotor side is the same.

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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 hexagon socket screws.

SVIL13COM0558AB

1

SVIL13COM0559AB

2

SVIL13COM0560AB

3

2. Remove the vibromotor.

3. Remove the coupling.

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4. Mount the pressure plate with the hexagon bolts.

SVIL13COM0561AB

4

SVIL13COM0562AB

5

SVIL13COM0563AB

6

SVIL13COM0565AB

7

5. Remove the hexagon bolts.

6. Use the device to push the wheel disk away from the drive bearing.

7. Screw in an M16 eye bolt.

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8. Lift the wheel disk away with the crane and safely put it down.

SVIL13COM0564AB

8

SVIL13COM0550AB

9

9. Loosen the pinion fastener.

10. Remove the pinion fastener.

SVIL13COM0551AB

10

SVIL13COM0552AB

11

11. Pull the pinion off the shaft.

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12. Remove the hexagon bolts and spring washers.

SVIL13COM0553AB

12

SVIL13COM0554AB

13

SVIL13COM0555AB

14

SVIL13COM0297AB

15

13. Screw in the eye bolts.

14. Attach the tackle to the eye bolts.

15. Lift the bearing flange away from the roller drum and place it on the workbench.

16. Remove the shaft sealing ring.

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17. Remove the inner securing ring.

SVIL13COM0298AB

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Compaction drums - Assemble Drive - bearing - flange 1. Insert the bearing into the drive bearing flange.

SVIL13COM0238AB

1

SVIL13COM0239AB

2

SVIL13COM0240AB

3

SVIL13COM0241AB

4

2. Place the drive bearing flange under the press.

3. Press the bearing in.

4. Install the inner securing ring.

5. Position the shaft sealing ring.

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6. Press in the shaft sealing ring.

SVIL13COM0242AB

5

SVIL13COM0269AB

6

SVIL13COM0289AB

7

SVIL13COM0235AB

8

7. Grease the shaft sealing ring and the bearing with 10 g (0.35 oz) of CASE AKCELA GRADE F GEAR LUBE.

8. Grease the drive bearing flange, gasket surface with CASE AKCELA GRADE F GEAR LUBE.

9. Insert the shaft sealing ring into the clamp ring. The dust lip must face upwards.

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10. Press the shaft sealing ring all the way in.

SVIL13COM0236AB

9

SVIL13COM0237AB

10

SVIL13COM0287AB

11

SVIL13COM0288AB

12

11. Grease the groove for the X-ring.

12. Place the X-ring inside the groove.

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13. Re-grease the shaft sealing ring and the X-ring.

SVIL13COM0290AB

13

SVIL13COM0251AB

14

SVIL13COM0253AB

15

14. Slide the clamp ring over the hub all the way down.

15. Fill the shaft sealing ring with grease.

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

SVIL13COM0243AB

16

SVIL13COM0254AB

17

SVIL13COM0244AB

18

SVIL13COM0257AB

19

17. Put LOCTITE® 242® into the threaded holes.

18. De-grease (clean) the bearing seat with alcohol.

19. Apply LOCTITE® 603™ evenly to the bearing seat.

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20. Place the drive bearing flange under the press.

SVIL13COM0245AB

20

SVIL13COM0255AB

21

SVIL13COM0256AB

22

SVIL13COM0245AB

23

21. Heat up the bearing to an approximate temperature of 112 °C (234 °F).

22. Slide the bearing over the hub.

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23. Push the bearing all the way down with the press.

SVIL13COM0292AB

24

SVIL13COM0246AB

25

SVIL13COM0258AB

26

SVIL13COM0259AB

27

24. Grease the bearing.

25. Mount the pressure plate on the wheel disk.

26. Align the wheel disk relative to the clamp ring.

27. Press the wheel disk over the bearing.

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

29. Install the bolts and washers.

Torque them to 50 N·m (37 lb ft).

SVIL13COM0260AB

28

SVIL13COM0247AB

29

SVIL13COM0312AB

30

30. Put 250 g (8.8 oz) of CASE AKCELA GRADE F GEAR LUBE into the drive bearing flange housing.

NOTE: Do not exceed the total amount of grease ( 250 g (8.8 oz)) in the drive bearing flange housing.

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. Place the bearing flange under the press.

2. Push out the vibro bearing.

SVIL13COM0299AB

1

SVIL13COM0293AB

2

SVIL13COM0294AB

3

3. Insert the pressure plate into the flange.

4. Screw the puller onto the clamp ring.

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5. Heat up the bearing to an approximate temperature of 200 °C (392 °F).

SVIL13COM0295AB

4

SVIL13COM0296AB

5

SVIL13COM0266AB

6

SVIL13COM0261AB

7

6. Pull the bearing off the flange.

7. Remove the seals.

8. Clean and inspect the parts.

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

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

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11. Turn the roller drum 180° by drum caliper and crane.

SVIL13COM0265AB

8

SVIL13COM0311AB

9

12. Remove the hexagon bolts and spring washers.

13. Pull the bearing flange off the roller drum.

14. Remove the hexagon socket bolts.

SVIL13COM0566AB

10

SVIL13COM0567AB

11

15. Remove the cover from the bearing housing.

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16. Remove the shaft sealing ring from the bearing housing.

SVIL13COM0568AB

12

SVIL13COM0569AB

13

SVIL13COM0570AB

14

SVIL13COM0571AB

15

17. Remove the inner securing ring.

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18. Place the bearing housing under the press.

19. Push the bearing out.

SVIL13COM0572AB

16

SVIL13COM0573AB

17

SVIL13COM0574AB

18

20. Clean all the parts and check them for damage.

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Compaction drums - Assemble Vibro - bearing - flange 1. Place the bearing in the housing.

SVIL13COM0229AB

1

SVIL13COM0230AB

2

SVIL13COM0231AB

3

SVIL13COM0232AB

4

2. Place the housing under the press.

3. Press the bearing in.

4. Install the inner securing ring.

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5. Place the shaft sealing ring in the bearing housing.

SVIL13COM0233AB

5

SVIL13COM0234AB

6

SVIL13COM0252AB

7

SVIL13COM0262AB

8

6. Place the bearing housing under the press.

7. Press in the shaft sealing ring.

8. Turn the bearing housing 180°.

9. Insert the supporting disk.

10. Place the cover on top of the bearing housing.

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11. Use the hexagon socket screws to screw it onto the housing temporarily.

SVIL13COM0566AB

9

12. Clean the hole in the roller drum.

13. Lubricate the bearing seat with LOCTITE® ANTI-SEIZE.

SVIL13COM0248AB

10

SVIL13COM0263AB

11

SVIL13COM0311AB

12

14. Grease the bearing housing with 50 g (1.8 oz) of CASE AKCELA GRADE F GEAR LUBE.

15. Insert the bearing housing into the roller drum.

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

17. Torque the hexagon bolts to 48.0 N·m (35.4 lb ft).

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18. Turn the roller drum 180° by drum caliper and crane.

SVIL13COM0557AB

13

SVIL13COM0261AB

14

SVIL13COM0264AB

15

SVIL13COM0266AB

16

19. Suspend the pre-assembled vibro shaft from the crane.

20. Grease the bearing seat and the SpeedySleeve ring.

21. Lower the vibro shaft into the roller drum.

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22. Remove the lifting device.

23. Grease the bearing seat and the SpeedySleeve ring.

SVIL13COM0267AB

17

SVIL13COM0268AB

18

SVIL13COM0258AB

19

SVIL13COM0249AB

20

24. Insert the support sleeve into the wheel disk.

25. Mount the pressure plate.

26. Put LOCTITE® 242® into the threaded holes.

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27. Align the drive bearing flange with the mounting holes.

28. Lower it into the roller drum using the crane.

SVIL13COM0270AB

21

SVIL13COM0271AB

22

SVIL13COM0272AB

23

SVIL13COM0273AB

24

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

30. Install the drive bearing flange with the bolts and spring washers and torque them to 50 N·m (37 lb ft).

31. Remove the pressure plate and support the sleeve.

32. Insert the pinion.

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33. Apply LOCTITE® 242® to the pinion-securing screw.

34. Torque the screw and spring washer with to 25.0 N·m (18.4 lb ft).

SVIL13COM0274AB

25

SVIL13COM0275AB

26

SVIL13COM0276AB

27

SVIL13COM0282AB

28

35. Tighten the pinion-securing screw.

36. Position the roller drum horizontally and secure it.

37. Remove the temporary inner hexagon socket screws.

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38. Remove the temporary outer hexagon bolts.

SVIL13COM0277AB

29

SVIL13COM0278AB

30

SVIL13COM0279AB

31

SVIL13COM0280AB

32

39. Remove the support disk.

40. Apply LOCTITE® 574™ to the bearing housing surface.

41. Put LOCTITE® 242® in the 12 inner and outer threaded holes.

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42. Lightly re-grease the bearing.

SVIL13COM0281AB

33

SVIL13COM0283AB

34

SVIL13COM0284AB

35

43. Torque the hexagon bolts to 50 N·m (37 lb ft).

44. Torque the hexagon socket screws to 25 N·m (18.4 lb ft).

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45. Check the axial play: 0.75 – 2.25 mm (0.03 – 0.09 in)

SVIL13COM0285AB

36

SVIL13COM0286AB

37

SVIL13COM0312AB

38

SVIL13COM0313AB

39

46. Insert the coupling sleeve.

47. Grease the inside of the flange with CASE AKCELA GRADE F GEAR LUBE. Total amount of grease for the drive bearing flange = 250.0 g (8.8 oz).

48. Apply LOCTITE® 574™ to the vibromotor flange.

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49. Insert the vibromotor.

SVIL13COM0559AB

40

SVIL13COM0558AB

41

SVIL13COM0250AB

42

SVIL13COM0556AB

43

50. Apply LOCTITE® 242® to the hexagon socket screws.

51. Install the screws and torque them to 25 N·m (18.4 lb ft).

52. Install the hexagon socket cover screw with the gasket (copper).

53. Apply LOCTITE® 242® to the threaded pins of the rubber elements.

Next operation: Install the drum. Refer to Compaction drums - Install (44.160) Next operation: 48142070 15/09/2017

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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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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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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 DV36 DV45

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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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 DV36 DV45

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33

Compaction drums - Assemble Vibro - bearing - flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46

Compaction drums - Component identification - drum ballasts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Compaction drums - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Compaction drums - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Compaction drums - Disassemble Drive - bearing - flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28

Compaction drums - Disassemble Vibro - bearing - flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41

Compaction drums - Install the drum ballasts (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

Compaction drums - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

Compaction drums - Remove the drum ballasts (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

Compaction drums - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

Compaction drums - Replace the rubber element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58

Compaction rear drum shaft - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

66

Compaction rear drum shaft - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82

Compaction rear drum shaft - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59

Compaction rear drum shaft - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75

(*) See content for specific models 48142070 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. © 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.

48142070 15/09/2017 EN

SERVICE MANUAL Electrical systems DV36 DV45CC DV45

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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

DV36 DV45CC DV45

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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 Ω.

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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

DV36 DV45CC DV45

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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 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

Hydrostatic control solenoids Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Electrical systems - Hydrostatic drive control system

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

SVIL13COM0498AB

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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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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Hydrostatic control solenoids - Electrical test The drive pump’s solenoid cannot be actuated mechanically.

SVIL13COM0615AB

1

SVIL13COM0616AB

2

SVIL13COM0617AB

3

1. Unscrew the knurled nut.

2. Pull out the solenoid.

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3. Unscrew the solenoid valve.

SVIL13COM0618AB

4

SVIL13COM0619AB

5

SVIL13COM0620AB

6

SVIL13COM0621AB

7

4. Measure the solenoid’s Y3 / Y4 resistance.

There should be a value of 5.4 – 6.2 Ω.

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

6. The valve must be visibly actuated.

7. Install the solenoid and torque the nut to 5 – 6 N·m (3.7 – 4.4 lb ft).

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Index Electrical systems - 55 Hydrostatic drive control system - 019 Hydrostatic control solenoids - Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

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

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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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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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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 K15 K16 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, front vibration Relay, rear vibration 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 S14 S15 S16 S17 S18 S51 S52 S53 S54 Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8 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 Switch, vibration selector Operating lever sensor, left Operating lever switch, left Switch, parking brake Battery cutoff switch Sensor, seat contact Sensor, brake pressure Sensor, hydraulic oil temperature Sensor, diesel tank Pull-in/holding solenoid Valve, locking brake Drive pump, forwards Drive pump, backwards Valve, front vibration Valve, rear vibration Valve, large amplitude vibration Valve, small frequency vibration Shutoff valve, sprinkler pump

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Comments

Option

Option Option Option

Electrical systems - Harnesses and connectors

RAIL13COM0025JA

1

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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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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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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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Fuse and relay box - Component localization - Engine Pos. F21 F22 F23 F24 K2 K3 K7 K15 K16

Designation Pull-in solenoid 40 A Diesel pump, alternator 15 A Reserve 15 A Reserve 10 A Timer 0.5 s Relay, pull-in solenoid Relay, starting interlock Relay, vibration Relay, vibration

NOTE: (K2) is located on the back of the metal sheet.

SS12K200

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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

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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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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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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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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

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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

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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 Ω 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: 48142070 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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Electrical systems - Electronic modules

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

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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

DV36 DV45CC DV45

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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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-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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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 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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-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 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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Electrical systems - FAULT CODES

-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 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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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 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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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 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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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 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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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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Electrical systems - FAULT CODES

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 Ω or more than 100 Ω. 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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Electrical systems - FAULT CODES

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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Electrical systems - FAULT CODES

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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Electrical systems - FAULT CODES

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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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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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. © 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.

48142070 15/09/2017 EN

SERVICE MANUAL Tools DV36 DV45CC DV45

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Contents Tools - 89

[89.165] Water kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89.1

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Tools - 89 Water kit - 165

DV36 DV45CC DV45

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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

SS13A777

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 Mounting plate Oval head screw Washer Hexagon head screw Cable Adhesive clip Socket head cap screw Washer Washer Hexagon head screw Holding plate Screwed elbow socket

Pos. 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

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Designation 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 Adjustable male stud run Rubber cushion 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. © 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.

48142070 15/09/2017 EN

SERVICE MANUAL Platform, cab, bodywork, and decals DV36 DV45CC DV45

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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

DV36 DV45CC DV45

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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

DV36 DV45CC DV45

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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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Platform, cab, bodywork, and decals - Operator platform less cab

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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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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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 - 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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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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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. © 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.

48142070 15/09/2017 EN

48142070 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. © 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.

48142070 15/09/2017 EN