Case DV36 DV45CC DV45 Vibratory Roller Operator's Manual Part number 48142069 - PDF DOWNLOAD

ORIGINAL INSTRUCTIONS

DV36 DV45CC DV45 Vibratory Roller

OPERATOR’S MANUAL

Part number 48142069 5th edition English April 2017 Replaces part number 47916992

Contents 1 GENERAL INFORMATION Note to the owner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Intended use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Your compactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Electro-Magnetic Compatibility (EMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Operator's manual storage on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Machine orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Machine components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Emission control system Warranty – USA only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

2 SAFETY INFORMATION Safety rules and signal word definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 California proposition 65 warning — California Proposition 65 Warning . . . . . . . . . . . . . . . . . . 2-9 Ecology and the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Hand signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

3 CONTROLS AND INSTRUMENTS Access to operator's platform Proper entry and exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Operator's seat Operator's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Forward controls Switches and control lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Front controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Vandalism protection cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Left-hand side controls Left-hand side controls (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Right-hand side controls Right-hand side controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Heated seat (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Rearward controls Rotating beacon (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Water level gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Backup alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Exterior controls Roller drum scrapers (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Battery master switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Display Display screens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

4 OPERATING INSTRUCTIONS Commissioning the unit Run-in period of a new machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Before starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Starting the unit Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Pre-heating the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Assisted starting (Jump-starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Stopping the unit Stopping the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Moving the unit Machine travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

5 TRANSPORT OPERATIONS Shipping transport Articulated joint lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transport on a trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Roll Over Protective Structure (ROPS) Fold up/down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1 5-2 5-3 5-4

Recovery transport Towing the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

6 WORKING OPERATIONS General information Vibration operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Sprinkling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Emulsion sprinkling (DV45CC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

7 MAINTENANCE General information General maintenance information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Torque charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended engine oil for operating temperature ranges. . . . . . . . . . . . . . . . . . . . . . . . . . .

Opening the hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Biodiesel fuel - Biodiesel fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diesel fuel - Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Consumables and capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1 7-1 7-3 7-4 7-5 7-7 7-8

Maintenance planning Maintenance chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

Every 10 hours of operation or daily Fuel level - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil level - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic oil level - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine coolant level - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sprinkler system - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Roller drum scrapers - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air intake - Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel filter water separator - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air filter service indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery charge - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water level indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tire pressure (DV45CC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emulsion level (DV45CC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-11 7-12 7-13 7-15 7-16 7-17 7-18 7-18 7-19 7-19 7-20 7-21 7-21

Initial 50 hours Engine oil and filter (Initial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

Every 50 hours or weekly Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24 Air filter vacuum valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25 Seat switch and emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

Every 100 hours or monthly Steering cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27

Initial 250 hours Engine oil and filter (Initial) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27

Initial 500 hours Ventilation filter for the hydraulic oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30 Hydraulic oil and filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31

Every 500 hours of operation or every 6 months Fuel filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clean the fuel filter water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine air filter - Replace. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-35 7-37 7-38 7-40

Every 1000 hours or annually Ventilation filter for the hydraulic oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic oil and filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel tank sediment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Articulated joint pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pendulum joint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-42 7-43 7-47 7-48 7-49

As required Fuel tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic oil and filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Articulated joint pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pendulum joint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front work lights and parking lights (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Turn signal and flasher bulb (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear work light and tail lights (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rotating beacon light (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water tank and sprinkler - Drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water tank - Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sprinkler nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pneumatic wheel scrapers (DV45CC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-50 7-51 7-55 7-56 7-57 7-58 7-61 7-62 7-63 7-64 7-65 7-66 7-68 7-70 7-70 7-70

Fuse and relay locations Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-71

Storage Short-term preservation and storage for 1-2 month . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-72 Machine preservation and storage for more than two months . . . . . . . . . . . . . . . . . . . . 7-73 Storage in freezing conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73

8 TROUBLESHOOTING Fault code resolution Error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

9 SPECIFICATIONS General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Consumables and capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

1 - GENERAL INFORMATION

1 - GENERAL INFORMATION###_1_### Note to the owner This manual contains important information about the safe operation, adjustment, and maintenance of your machine.

Refer to the table of contents in this manual as an outline or guide to information about your machine. Use the index at the end of this manual to locate specific items about your machine. The machine conforms to current safety regulations.

Use this manual as a guide. Service your machine properly and at the suggested intervals. Regular maintenance and correct operation will ensure that your machine will remain a reliable working tool for a long time. If you need more information, contact your CASE CONSTRUCTION dealer.

DO NOT operate or permit anyone to operate or service this machine until you or the other persons have read and understand the safety, operation, and maintenance instructions in this manual. Use only trained operators who have demonstrated the ability to operate and service this machine correctly and safely.

The information in this manual is provided on the basis of information that was available at the time that the manual was written. Settings, procedures, part numbers, software, and other items can change. These changes can affect the service of the machine. Ensure that you have the complete and most current information from your dealer before you start any machine operation.

Store this operator's manual in the manual compartment equipped on this machine. Make sure this manual is complete and in good condition. Consult your dealer to obtain additional manuals or manuals in other languages. An Association of Equipment Manufacturers (AEM) safety booklet is included with each machine. Take the time to read the booklet and understand its content.

Contact your CASE CONSTRUCTION dealer for any further information or assistance about your machine. Your dealer has CASE CONSTRUCTION –approved service parts. Your dealer has technicians with special training that know the best methods of repair and maintenance for your machine. CASE CONSTRUCTION customer assistance is also available. Go to www.casece.com.

ATTENTION: The fuel system and engine on your machine are designed and built to government emissions standards. Tampering by dealers, customers, operators, and users is strictly prohibited by law. Failure to comply could result in government fines, rework charges, invalid warranty, legal action, and possible confiscation of the machine until rework to original condition is completed. Engine service and/or repairs must be done by a certified technician only!

1-1

1 - GENERAL INFORMATION

Intended use DANGER Illustrations in this manual may show protective shielding open or removed to better illustrate a particular feature or adjustment.

Replace all shields before operating the machine.

Failure to comply will result in death or serious injury.

D0118A

WARNING Avoid injury!

Using the machine for purposes other than or beyond the intended use is not allowed; for example: - for the transportation of persons, - as a working platform, - for pulling attached loads, - for pulling or transporting loads without the intended working equipment.

Failure to comply could result in death or serious injury.

W1142B

CAUTION Equipment failure could cause accident or injury!

Tampering with or changing the setting of any hydraulic system valve is strictly forbidden.

Failure to comply could result in minor or moderate injury.

C0160A

This compactor is intended for use on small and medium-sized building sites. Use only approved accessories and attachments designed for your machine. Consult your dealer on changes, additions or modifications that may be required for your machine. Do not make any unauthorized modifications to your machine.

This compactor has been built with the most advanced technology and in accordance with recognized safety rules.

The compactor must be used according to its intended use, respecting the safety and precautionary rules and strictly following the operating instructions. Any functional disorders, especially those affecting the safety of the compactor, should therefore be rectified immediately.

The manufacturer/supplier cannot be held responsible for any damage resulting from unintended use. The risk involved in such misuse lies entirely with the user.

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

Carefully read this operator’s manual and store it in the manual compartment under the engine hood. Instructions concerning safety, operation and maintenance provided in this manual have been developed to permit safe service and operation of this compactor.

In the event of queries or suggestions relevant to your compactor do not hesitate to contact your dealer. Dealers have qualified and trained personnel as well as original spare parts and suitable equipment to carry out all necessary maintenance.

Do not use this compactor for any applications or purposes other than those described in this manual. If you use this compactor for duties involving the use of attachments, accessories, or special tools, consult your dealer to make sure that the adaptations or modifications carried out are in conformity with the compactor’s technical specifications and with current regulations on safety.

Any modifications or adaptations which are not approved by the manufacturer may invalidate the machine’s original conformity with safety requirements.

Spare parts The “non-genuine” spare parts have not been checked and authorized by the manufacturer. The assembly and/or use of such products may have negative effects on the machine design features and could impair its operation safety.

CASE CONSTRUCTION is not liable for any damage caused by “non-genuine” spare parts or accessories.

1-2

1 - GENERAL INFORMATION

NOTE: Each compactor is supplied complete with a copy of this manual. Descriptions and illustrations provided herein are not binding. The manufacturer, provided that the basic characteristics of compactor types described and shown in this manual remain the same, reserves the right to change components, parts and accessories supplied without any commitment to timely update this publication, and this any time it deems it convenient for improvement purposes or due to commercial or manufacturing requirements. For exact information, please contact your dealer.

1-3

1 - GENERAL INFORMATION

Your compactor

RAIL16COM0158FA

1

DV36 and DV45

RAIL16COM0144FA

DV45CC 1-4

2

1 - GENERAL INFORMATION

Electro-Magnetic Compatibility (EMC) Interference may arise as a result of add‐on equipment that may not necessarily meet the required standards. As such interference can result in serious malfunction of the unit and/or create unsafe situations, you must observe the following: • The maximum power of emission equipment (radio, telephones, etc.) must not exceed the limits imposed by the national authorities of the country where you use the machine • The electro‐magnetic field generated by the add‐on system should not exceed 24 V/m at any time and at any location in the proximity of electronic components • The add‐on equipment must not interfere with the functioning of the on board electronics Failure to comply with these rules will render the CASE CONSTRUCTION warranty null and void.

1-5

1 - GENERAL INFORMATION

Product identification Model, Product Identification Number (PIN), and year of manufacture Record the machine Product Identification Number (PIN) and additional machine information including the model and the component serial numbers in the spaces below. Always supply this information to your dealer when you order parts, obtain information, or require assistance. Keep a record of these numbers and your Manufacturer’s Statement of Origin in a safe place. If the machine is stolen, report the numbers to your local law enforcement agency.

Machine identification Model name Product Identification Number (PIN) Model year

The PIN plate is located on the chassis below the steering column.

RAIL14COM0348BA

1

RAIL15COM0301AA

2

RAIL14COM0260AA

3

Roll-Over Protective Structure (ROPS)

The ROPS serial number plate is located on the protective structure inside the cab.

1-6

1 - GENERAL INFORMATION

Engine make and model

Engine serial number

The serial number plate is on top of the engine.

RAIL13SSL0071BA

1-7

4

1 - GENERAL INFORMATION

Operator's manual storage on the machine The operator’s manual storage compartment is located under the engine hood.

READ THIS MANUAL COMPLETELY and make certain you understand the controls. All equipment has a limit.

Make sure you understand the speed, steering, stability, and load characteristics of this machine before you start to operate.

DO NOT remove this manual from the machine. See your dealer for additional manuals. Always keep the operator's manual in the storage compartment provided on the machine. The operator's manual must be available for use by all operators.

RAIL15COM0187AA

When you see this symbol read your operator's manual.

When you see this symbol refer to your service manual.

1-8

1

1 - GENERAL INFORMATION

Machine orientation The terms right-hand and left-hand, when used in this manual, indicate the right and left sides of the machine as seen from the operator's seat.

1.

2.

3.

4.

Left-hand side Front side Right-hand side Rear side

RAIL15COM0015AA

1-9

1

1 - GENERAL INFORMATION

Machine components Right-hand side controls

RAIL15COM0237FA

1. Emergency stop 2. Ignition switch

1

3. Speed adjusting lever 4. Travel control lever

1-10

1 - GENERAL INFORMATION

Left-hand side components

RAIL15COM0238FA

1. Roller frame (front) 2. Articulated joint lock

2

3. Hydraulic tank oil lever indicator 4. Emulsion filler neck cover (DV45CC only)

1-11

1 - GENERAL INFORMATION

Drain locations

RAIL15COM0239FA

1. Engine oil drain 2. Hydraulic oil drain

3

3. Fuel tank drain 4. Emulsion tank drain (DV45CC only)

1-12

1 - GENERAL INFORMATION

Front, right-hand side components

RAIL15COM0240GA

1. Product Identification Number (PIN) 2. Water filter 3. Fuel tank cap (diesel)

4

4. Roller drum scraper 5. Front sprinkler 6. Document holder under the hood

1-13

1 - GENERAL INFORMATION

Rear, left-hand side components

RAIL15COM0241FA

1. Water tank fill 2. Water level gauge 3. Tow points

5

4. Roller drum scraper 5. Rear sprinkler 6. Water pump

1-14

1 - GENERAL INFORMATION

Engine compartment overview

RAIL15COM0242FA

1.

2.

3.

4.

5.

6.

Battery Engine oil filler neck Coolant filler neck Fuel filter Coolant level display Hydraulic oil filler neck

6

7. Hydraulic oil filter 8. Engine oil filter 9. Air-intake filter 10. Engine oil dipstick 11. Water separator 12. Air filter restriction indicator

Emission control system Warranty – USA only Your warranty rights and obligations California The California Air Resources Board (CARB), the United States Environmental Protection Agency (EPA) and YANMAR Co., Ltd. hereafter referred to as Yanmar, are pleased to explain the emission control system warranty on your 2013, 2014, or, 2015 industrial compression-ignition engine. California-certified, new off-road compression-ignition engines must be designed, built and equipped to meet the State’s stringent anti-smog standards. In the remaining forty nine (49) states, new non-road compression-ignition engines must be designed, built and equipped to meet the United States EPA emissions standards. Yanmar must warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your engine.

Your emission control system may include parts such as the fuel injection system, the air induction system, the electronic control system, the Exhaust Gas Recirculation (EGR) system, and the Diesel Particulate Filter (DPF) system.

Also included may be hoses, belts, connectors and other emission-related assemblies.

Where a warrantable condition exists, Yanmar will repair your non-road compression-ignition engine at no charge to you including diagnosis, parts and labor.

1-15

1 - GENERAL INFORMATION

Manufacturer’s warranty period: 2013, 2014, or 2015 model year off-road compression-ignition engines are warranted for the periods listed below. If any emission-related part on your engine is found to be defective during the applicable warranty period the part will be replaced by Yanmar.

If your engine is certified as And its maximum power is Variable speed or constant kW < 19 speed

And its rated speed is

The its warranty period is

Any speed

1,500 h or two (2) years whichever comes first. In the absence of a device to measure the hours of use, the engine has a warranty period of two (2) years.

1,500 h or two (2) years whichever comes first. In the absence of a device to measure the hours of use, the engine has a warranty period of two (2) years.

3,000 h or five (5) years whichever comes first. In the absence of a device to measure the hours of use, the engine has a warranty period of five (5) years.

3,000 h or five (5) years whichever comes first. In the absence of a device to measure the hours of use, the engine has a warranty period of five (5) years.

3,000 h or five (5) years whichever comes first. In the absence of a device to measure the hours of use, the engine has a warranty period of five (5) years.

Constant speed

19 ≤ kW <37

3,000 RPM or higher

Constant speed

19 ≤ kW <37

Less than 3,000 RPM

Variable speed

19 ≤ kW <37

Any speed

Variable speed or constant kW ≥ 37 speed

Any speed

1-16

1 - GENERAL INFORMATION

Warranty coverage: This warranty is transferable to each subsequent purchaser for the duration of the warranty period. Repair or replacement of any warranted part will be performed at an authorized Yanmar industrial engine dealer or distributor.

Warranted parts not scheduled for replacement as required maintenance in the owner's manual shall be warranted for the warranty period. Warranted parts scheduled for replacement as required maintenance in the owner's manual are warranted for the period of time prior to the first scheduled replacement. Any warranted parts scheduled for replacement as required maintenance that are repaired or replaced under warranty shall be warranted for the remaining period of time prior to the first scheduled replacement. Any part not scheduled for replacement that is repaired or replaced under warranty shall be warranted for the remaining warranty period.

During the warranty period, Yanmar is liable for damages to other engine components caused by the failure of any warranted part during the warranty period.

Any replacement part which is functionally identical to the original equipment part in all respects may be used in the maintenance or repair of your engine, and shall not reduce Yanmar’s warranty obligations. Add-on or modified parts that are not exempted may not be used. The use of any non-exempted add-on or modified parts shall be grounds for disallowing a warranty.

Warranted parts: This warranty covers engine components that are a part of the emission control system of the engine as delivered

by Yanmar to the original retail purchaser. Such components may include the following: • Fuel injection system (Including Altitude compensation system) • Cold start enrichment system • Intake manifold and Air intake throttle valve • Turbocharger systems • Exhaust manifold • Positive crankcase ventilation system • Charge Air Cooling systems • Exhaust Gas Recirculation (EGR) systems • Exhaust gas after treatment (Diesel Particulate Filter (DPF)) system • Electronic Control units, sensors, solenoids and wiring harnesses associated with the above systems.

• Hoses, belts, connectors, and assemblies associated with the above systems • Emission Control Information Label Since emissions-related parts may vary slightly between models, certain models may not contain all of these parts and other models may contain the functional equivalents.

Exclusions: Failures other than those arising from defects in material and/or workmanship are not covered by this warranty. The warranty does not extend to the following: malfunctions caused by abuse, misuse, improper adjustment, modification, alteration, tampering, disconnection, improper or inadequate maintenance or use of non-recommended fuels and lubricating oils; accident caused damage, and replacement of expendable items made in connection with scheduled maintenance. Yanmar disclaims any responsibility for incidental or consequential damages such as loss of time, inconvenience, loss of use of equipment/engine or commercial loss.

1-17

1 - GENERAL INFORMATION

Owner’s warranty responsibilities: As the off-road compression-ignition engine owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. Yanmar recommends that you retain all documentation, including receipts, covering maintenance on your off-road compression-ignition engine, but Yanmar cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

Yanmar may deny your warranty coverage if your off-road compression-ignition engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

Your engine is designed to operate on diesel fuel only. Use of any other fuel may result in your engine no longer operating in compliance with CARB and EPA emissions requirements.

You are responsible for initiating the warranty process. You must present your engine to a Yanmar dealer as soon as a problem exists. The warranty repairs should be completed by the dealer as expeditiously as possible. If you have any questions regarding your warranty rights and responsibilities, or would like information on the nearest Yanmar dealer or authorized service center, you should contact Yanmar America Corporation.

Website: www.yanmar.com E-mail: CS_support@yanmar.com Toll free telephone number: 1–800–872–2867, 1–855–416–7091

1-18

2 - SAFETY INFORMATION

2 - SAFETY INFORMATION###_2_### Safety rules and signal word definitions Personal safety This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury.

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

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

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

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

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

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

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

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

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

2-1

2 - SAFETY INFORMATION

Safety rules General safety rules Use caution when you operate the machine on slopes. Raised equipment, full tanks and other loads will change the center of gravity of the machine. The machine can tip or roll over when near ditches and embankments or uneven surfaces.

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

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

When digging or using ground-engaging attachments, be aware of buried cables. Contact local utilities to determine the locations of services.

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

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

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

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

• Make sure that all components are in good condition. Tighten all connections before you start the engine or pressurize the system.

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

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

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

Wear protective equipment when appropriate.

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

Make sure that all guards and shields are in good condition and properly installed before you operate the machine.

Never operate the machine with shields removed. Always close access doors or panels before you operate the machine.

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

A person or pet within the operating area of a machine can be struck or crushed by the machine or its equipment. DO NOT allow anyone to enter the work area.

Raised equipment and/or loads can fall unexpectedly and crush persons underneath. Never allow anyone to enter the area underneath raised equipment during operation.

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

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

Start the engine only from the operator’s seat. If you bypass the safety start switch, the engine can start with the transmission in gear. Do not connect or short across terminals on the starter solenoid. Attach jumper cables as described in the manual. Starting in gear may cause death or serious injury.

Always keep windows, mirrors, and all lighting clean to provide the best possible visibility while you operate the machine.

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

2-2

2 - SAFETY INFORMATION

Before you leave the machine: 1. Park the machine on a firm, level surface.

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

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

4. Lower all hydraulic equipment — Implements, header, etc.

5. Turn off the engine and remove the key.

When, due to exceptional circumstances, you would decide to keep the engine running after you leave the operator’s station, then you must follow these precautions: 1. Bring the engine to low idle speed.

2. Disengage all drive systems.

3.

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

Make sure all drive systems are fully disengaged.

Failure to comply could result in death or serious injury.

W0113A

Shift the transmission into neutral.

4. Apply the parking brake.

General maintenance safety Keep the area used for servicing the machine clean and dry. Clean up spilled fluids.

Service the machine on a firm, level surface.

Install guards and shields after you service the machine.

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

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

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

Unsupported hydraulic cylinders can lose pressure and drop the equipment, causing a crushing hazard. Do not leave equipment in a raised position while parked or during service, unless the equipment is securely supported.

Jack or lift the machine only at jack or lift points indicated in this manual.

Incorrect towing procedures can cause accidents. When you tow a disabled machine follow the procedure in this manual. Use only rigid tow bars.

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

Stop the engine and remove the key before you connect or disconnect electrical connections.

Scalding can result from incorrect removal of coolant caps. Cooling systems operate under pressure. Hot coolant can spray out if you remove a cap while the system is hot. Allow the system to cool before you remove the cap. When you remove the cap, turn it slowly to allow pressure to escape before you completely remove the cap.

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

The engine, transmission, exhaust components, and hydraulic lines may become hot during operation. Take care when you service such components. Allow surfaces to cool before you handle or disconnect hot components. Wear protective equipment when appropriate.

When welding, follow the instructions in the manual. Always disconnect the battery before you weld on the machine.

Always wash your hands after you handle battery components.

2-3

2 - SAFETY INFORMATION

Fire and explosion prevention Fuel or oil that is leaked or spilled on hot surfaces or electrical components can cause a fire.

Crop materials, trash, debris, bird nests, or flammable material can ignite on hot surfaces.

Always have a fire extinguisher on or near the machine.

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

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

At least once each day, remove debris accumulation around moving components such as bearings, pulleys, belts, gears, cleaning fans, etc. More frequent cleaning of your machine may be necessary depending on the operating environment and conditions.

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

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

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

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

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

General battery safety Always wear eye protection when you work with batteries.

Do not create sparks or have open flame near a battery.

Ventilate the area when you charge a battery or use a battery in an enclosed area.

Disconnect the negative (-) terminal first and reconnect the negative (-) terminal last.

When you weld on the machine, disconnect both terminals of the battery.

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

When you use auxiliary batteries or connect jumper cables to start the engine, use the procedure shown in the operator’s manual. Do not short across terminals.

Follow the manufacturer’s instructions when you store and handle batteries.

Battery post, terminals, and related accessories contain lead and lead compounds. Wash hands after handling. This is a California Proposition 65 warning.

Battery acid causes burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes, or clothing. Antidote (external): Flush with water. Antidote (eyes): flush with water for 15 minutes and seek medical attention immediately.

Antidote (internal): Drink large quantities of water or milk. Do not induce vomiting. Seek medical attention immediately.

Keep out of reach of children and other unauthorized persons.

Operator presence system Your machine is equipped with an operator presence system to prevent the use of some features while the operator is not in the operator’s seat.

Never disconnect or bypass the operator presence system.

2-4

2 - SAFETY INFORMATION

If the operator presence system is inoperable, then it must be repaired.

Seat belts Seat belts must be worn at all times.

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

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

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

• Replace all parts that have damage or wear.

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

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

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

• Keep seat belts clean and dry.

• Clean belts only with soap solution and warm water.

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

Pull the right-hand belt from the seat belt retractor. Fasten the metal belt end into the left-hand buckle.

RCIL10CWL037AAL

1

RCIL10CWL083FAL

2

Press the red button on the left-hand seat belt mechanism to release the seat belt.

2-5

2 - SAFETY INFORMATION

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

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

The protective structure and interconnecting components are a certified system. Any damage, fire, corrosion, or modification will weaken the structure and reduce your protection. If this occurs, THE PROTECTIVE STRUCTURE MUST BE REPLACED so that it will provide the same protection as a new protective structure. Contact your dealer for protective structure inspection and replacement.

After an accident, fire, tip over, or roll over, the following MUST be performed by a qualified technician before returning the machine to field or job-site operations: • The protective structure MUST BE REPLACED. • The mounting or suspension for the protective structure, operator’s seat and suspension, seat belts and mounting components, and wiring within the operator’s protective system MUST be carefully inspected for damage.

• All damaged parts MUST BE REPLACED. DO NOT WELD, DRILL HOLES, ATTEMPT TO STRAIGHTEN, OR REPAIR THE PROTECTIVE STRUCTURE. MODIFICATION IN ANY WAY CAN REDUCE THE STRUCTURAL INTEGRITY OF THE STRUCTURE, WHICH COULD CAUSE DEATH OR SERIOUS INJURY IN THE EVENT OF FIRE, TIP OVER, ROLL OVER, COLLISION, OR ACCIDENT. Seat belts are part of your protective system and must be worn at all times. The operator must be held to the seat inside the frame in order for the protective system to work.

Backup alarm system Do not disconnect backup alarm system if so equipped.

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

Do Not Operate tag Before you start servicing the machine, attach a ‘Do Not Operate’ warning tag to the machine in an area that will be visible.

Hazardous chemicals If you are exposed to or come in contact with hazardous chemicals you can be seriously injured. The fluids, lubricants, paints, adhesives, coolant, etc. required for the function of your machine can be hazardous. They may be attractive and harmful to domestic animals as well as humans.

Material Safety Data Sheets (MSDS) provide information about the chemical substances within a product, safe handling and storage procedures, first aid measures, and procedures to take in the event of a spill or accidental release.

MSDS are available from your dealer.

Before you service your machine check the MSDS for each lubricant, fluid, etc. used in this machine. This information indicates the associated risks and will help you service the machine safely. Follow the information in the MSDS, and on manufacturer containers, as well as the information in this manual, when you service the machine.

2-6

2 - SAFETY INFORMATION

Dispose of all fluids, filters, and containers in an environmentally safe manner according to local laws and regulations.

Check with local environmental and recycling centers or your dealer for correct disposal information.

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

Keep out of reach or children or other unauthorized persons.

Applied chemicals require additional precautions. Obtain complete information from the manufacturer or distributor of the chemicals before you use them.

Utility safety When digging or using ground-engaging equipment, be aware of buried cables and other services. Contact your local utilities or authorities, as appropriate, to determine the locations of services.

Make sure that the machine has sufficient clearance to pass in all directions. Pay special attention to overhead power lines and hanging obstacles. High voltage lines may require significant clearance for safety. Contact local authorities or utilities to obtain safe clearance distances from high voltage power lines.

Retract raised or extended components, if necessary. Remove or lower radio antennas or other accessories. Should a contact between the machine and an electric power source occur, the following precautions must be taken: • Stop the machine movement immediately.

• Apply the parking brake, stop the engine, and remove the key.

• Check if you can safely leave the cab or your actual position without contact with electrical wires. If not, stay in your position and call for help. If you can leave your position without touching lines, jump clear of the machine to make sure that you do not make contact with the ground and the machine at the same time.

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

Electrical storm safety Do not operate machine during an electrical storm.

If you are on the ground during an electrical storm, stay away from machinery and equipment. Seek shelter in a permanent, protected structure.

If an electrical storm should strike during operation, remain in the cab. Do not leave the cab or operator’s platform.

Do not make contact with the ground or objects outside the machine.

Mounting and dismounting Mount and dismount the machine only at designated locations that have handholds, steps, and/or or ladders.

Do not jump off of the machine.

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

Face the machine when you mount and dismount the machine.

Maintain a three-point contact with steps, ladders, and handholds.

Never mount or dismount from a moving machine.

Do not use the steering wheel or other controls or accessories as handholds when you enter or exit the cab or operator’s platform.

Working at heights When the normal use and maintenance of the machine requires you to work at heights:

2-7

2 - SAFETY INFORMATION

• Correctly use installed steps, ladders, and railings.

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

• Do not stand on surfaces that are not designated as steps or platforms.

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

Precautions specific to this machine DO NOT operate the machine on slopes with an angle that will cause the soil to break off (drop) under the machine.

DO NOT operate the machine on slopes with an angle that will cause the machine to slip.

Be aware of the bearing capacity of the subsoil. DO NOT operate the machine near the edge of a slope that could result in a landslide. DO NOT operate the machine near the edge of a trench that could result in the shoulder of the trench to break off (drop) along with the machine.

DO NOT operate the vibration option close to walls, cuts, or slopes. The walls, cuts, or slopes could slip and cover the machine.

DO NOT operate the vibration option close to buildings, facilities, or equipment. Vibration transfer impact could cause damage to the buildings, facilities, or equipment.

Application limits Temperature limit Humidity Terrain Slope up Slope down

Operation Storage -10 – 48 °C (14 – 118 °F) -25 – 48 °C (-13 – 118 °F) All-year operation and/or outdoor storage Level Level 30% with vibration 40% 40% without vibration 30% with vibration 40% 40% without vibration

2-8

2 - SAFETY INFORMATION

California proposition 65 warning — California Proposition 65 Warning

RCIL08CCH001EAA

1

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

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

2-9

2 - SAFETY INFORMATION

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

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

Battery recycling Batteries and electric accumulators contain several substances that can have a harmful effect on the environment if the batteries are not properly recycled after use.

Improper disposal of batteries can contaminate the soil, groundwater, and waterways. CASE CONSTRUCTION strongly recommends that you return all used batteries to a CASE CONSTRUCTION dealer, who will dispose of the used batteries or recycle the used batteries properly. In some countries, this is a legal requirement.

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

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

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

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

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

• Do not open the air-conditioning system yourself. It contains gases that should not be released into the atmosphere. Your CASE CONSTRUCTION dealer or air-conditioning specialist has a special extractor for this purpose and can recharge the system properly.

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

NHIL14GEN0038AA

1

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

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

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

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

2-10

2 - SAFETY INFORMATION

Hand signals When operating the machine, never attempt to carry out tasks calling for fine control or to work in areas where visibility is poor or impaired without seeking the assistance of a signal person. Make perfectly sure that you and the signal person understand the signals to be used.

Start the engine.

RAIL15DOZ0052AA

1

RAIL15DOZ0053AA

2

RAIL15DOZ0054AA

3

Stop the engine.

Come to me.

Wave hands back and forth (palms inward).

2-11

2 - SAFETY INFORMATION

Move away from me.

Wave hands back and forth (palms outward).

RAIL15DOZ0055AA

4

RAIL15DOZ0056AA

5

RAIL15DOZ0057AA

6

RAIL15DOZ0058AA

7

Go this far.

All stop and hold.

Stop Move one hand back and forth.

2-12

2 - SAFETY INFORMATION

Emergency stop Move both hands back and forth.

RAIL15DOZ0059AA

8

RAIL15DOZ0060AA

9

Raise the tool.

Lower the tool.

RAIL15DOZ0061AA

2-13

10

2 - SAFETY INFORMATION

Safety signs WARNING Avoid injury!

An illegible or missing safety sign can have far-reaching consequences. Inspect safety signs daily.

Clean and replace damaged safety signs as necessary.

Failure to comply could result in death or serious injury.

W0167A

The following safety signs are on your machine as a guide for your safety and for the safety of those working with you.

Walk around the machine and note the content and the location of all safety signs before you operate your machine.

Keep all safety signs clean and legible. Clean safety signs with a soft cloth, water, and a gentle detergent.

NOTICE: Do not use solvent, gasoline, or other harsh chemicals. Solvents, gasoline, and other harsh chemicals may damage or remove safety signs.

Replace all safety signs that are damaged, missing, painted over, or illegible. If a safety sign is on a part you or your dealer replaces, make sure that you our your dealer install the safety sign on the new part. See your dealer for replacement safety signs.

Safety signs that display the “Read operator’s manual” symbol direct you to the operator’s manual for further information regarding maintenance, adjustments, or procedures for particular areas of the machine. When a safety sign displays this symbol, consult the appropriate page of the operator’s manual.

Safety signs that display the “Read service manual” symbol direct you to the service manual. If you doubt your ability to perform service operations, contact your dealer.

2-14

2 - SAFETY INFORMATION

RAIL15COM0262GA

2-15

1

2 - SAFETY INFORMATION

RAIL15COM0263GA

2-16

2

2 - SAFETY INFORMATION

DANGER Explosion hazard Read the procedure in the Operator’s Manual before jump start or service the machine to avoid injury.

Failure to comply will result in death or serious injury.

Quantity: 1 47437573

47437573

3

47431348

4

47437574

5

(1) Location: On the front frame on the right-hand side under the battery.

WARNING Run over hazard Starting in gear could cause death. Start the engine from the operator seat only with the transmission control(s) in neutral. Failure to comply could result in death or serious injury.

Quantity: 1 47431348 (2) Location: On the side of the frame in the area of the starter.

WARNING Welding hazard Read Operator’s Manual before welding on the machine. Disconnect the alternator before welding on the machine. Failure to comply could result in death or serious injury.

Quantity: 1 47437574

(3) Location: On the steering column

2-17

2 - SAFETY INFORMATION

Fuel fill Filler neck for diesel fuel

Quantity: 1 47411742

47411742

6

(4) Location: On the front chassis, right-hand side, over the filler neck.

RAIL15COM0024AA

Lifting point Use these lifting points to lift the machine.

Quantity: 4 47411759

47411759

8

47411757

9

(5) Location: On the four wheel supports.

Tie down Use only the points identified with this sign to tie down the machine.

Quantity: 4 47411757

(6) Location: On the front and rear chassis, on the left and right, respectively.

2-18

7

2 - SAFETY INFORMATION

WARNING Crush hazard Maintain a safe distance from the machine. Risk of being crushed between the front frame and rear frame of the machine. Failure to comply could result in death or serious injury.

Quantity: 2 47411732

47411732

10

47411741

11

47411779

12

(7) Location: Near the steering joint on the left-hand side and the right-hand side of the machine.

Guaranteed sound power level Indicates the overall noise level produced by the roller.

Quantity: 1 47411741

(8) Location: On the rear chassis.

WARNING Entanglement hazard/ Hot surface hazard Maintain a safe distance from the rotating cooling fan, pulley and belt and the hot part of the machine.

Keep clear or stop the engine before servicing.

Failure to comply could result in death or serious injury.

Quantity: 1 47411779

(9) Location: On the left-hand side and the right-hand side of the radiator.

2-19

2 - SAFETY INFORMATION

Wear a seat belt Always wear the seat belt when in the driver’s seat.

Failure to comply could result in death or serious injury.

Quantity: 1 47411773

47411773

13

47411764

14

47411771

15

(10) Location: On the steering column.

Hearing protection is required Wear hearing protection when operating the machine if the machine does not have a cab.

Quantity: 1 47411764

(11) Location: On the steering column.

WARNING Wear of the locking brake Only operate the parking brake when at a standstill.

Only operate the emergency stop when at a standstill or in an emergency. After several operations of the locking brake while the roller is in motion, the brake test must be performed. Failure to comply could result in death or serious injury.

Quantity: 1 47411771

(12) Location: On the steering column

2-20

2 - SAFETY INFORMATION

WARNING Read Operator’s manual Before starting the machine, thoroughly read the safety measures and the instructions for controlling the machine and its actuators. The safety measures and the instructions can be found in the manuals that are supplied with the machine. Fasten the seat belt. Do not carry passengers or riders. Keep others away. Failure to comply could result in death or serious injury.

Quantity: 1 47411756 47411756

16

47411729

17

(13) Location: On the steering column and on the display screen.

WARNING Crush hazard Never operate the roller with the Roll Over Protective Structure (ROPS) folded down. Failure to comply could result in death or serious injury.

Quantity: 1 47411729

(14) Location: On the ROPS (rollover bar)

RAIL15COM0025AA

Damage to the electrical controls Never spray the water jet into electrical or electronic components. Never spray into the engine combustion air intake.

Quantity: 1 47411739

47411739

(15) Location: On the steering column.

2-21

19

18

2 - SAFETY INFORMATION

Drain for the engine oil

Quantity: 1 47411743

47411743

20

(16) Location: On the front chassis under the cooler.

RAIL15COM0188AA

Lifting the machine To lift the Machine use lifting device of adequate capacity. Before lifting, secure the machine articulation lock.

Quantity: 1 47479076

47479076

(17) Location: On the left–hand side of the machine.

2-22

22

21

2 - SAFETY INFORMATION

Hydraulic oil drain Drain for the hydraulic oil

Quantity: 1 47411747

47411747

23

(18) Location: On the front chassis.

RAIL15COM0178AA

2-23

24

2 - SAFETY INFORMATION

2-24

3 - CONTROLS AND INSTRUMENTS

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

Proper entry and exit WARNING Fall hazard!

When entering or exiting the cab, never use the control levers as handholds. Always mount and dismount the machine in a safe way. Maintain a three-point contact with steps, ladders, and/or handholds.

Failure to comply could result in death or serious injury.

W1340B

Proper entry or exit from the cab is the same on both sides.

• Use the steps and the hand holds when you enter or exit the operator’s platform.

• Do not use the steering wheel or other controls or accessories as hand holds.

• Face the machine and maintain a three point contact with the designated steps, ladders, and hand holds.

• Do not jump on or off the machine.

• Never mount or dismount from a moving machine.

• Make sure steps, ladders, and platforms remain clean and clear of debris and foreign substances. Surfaces may be slippery.

3-1

RAIL15COM0099AA

1

3 - CONTROLS AND INSTRUMENTS

Operator's seat

Operator's seat DANGER Loss of control hazard!

DO NOT make seat or steering adjustments while the machine is in motion. Ensure all adjustments are locked prior to use. Check the tightness of the securing screws and that the adjustment controls are working properly. Fitting and/or repairing the seat should only be performed by skilled personnel.

Failure to comply will result in death or serious injury.

D0008A

WARNING Avoid injury!

Before starting the engine, securely fasten the seat belt. The seat belt can help ensure your safety if it is properly used and maintained. Never wear a seat belt loosely or with slack in the belt system.

Never wear the belt if it is twisted or pinched between the seat structures.

Failure to comply could result in death or serious injury.

W0142A

Seat adjustment Backrest adjustment • Move the lever (1) up or down to adjust the backrest for your height.

Forward or backward adjustment • Pull the lever (2) slightly upward. Slide the seat forward or backward to place the seat in your desired position.

Horizontal adjustment • Pull the lever (3) slightly upward. Slide the seat left or right to place the seat in your desired position.

Operator weight adjustment • To reduce the spring tension of the seat, turn the adjusting knob (4) to the right.

• To increase the spring tension of the seat, turn the adjusting knob (4) to the left.

Weight adjustment is infinite in the range of 50 – 120 kg (110 – 265 lb).

RAIL15COM0023BA

3-2

1

3 - CONTROLS AND INSTRUMENTS

Retractable seat belt 1. Sit in the operator’s seat.

2. Pull the left-hand belt strap from the retractor across your lap.

3. Insert the metal end of the retractable belt into the latch mechanism on the right-hand side.

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

NOTE: A 3 in wide retractable seat belt is available as an option. Contact your dealer for details.

RAIL15COM0029AA

2

Deluxe seat (option) • The operator’s seat is equipped with two armrests.

• Move the armrests upward or downward.

Seat switch WARNING Run-over hazard!

Only operate the machine when sitting in the operator’s seat. Do not try to bypass the operator presence safety system by placing heavy objects on the seat.

Failure to comply could result in death or serious injury.

W0318A

Your machine is equipped with a seat switch (operator’s presence system). The machine can only operate when the seat switch is in the closed position, i.e. the operator is on the operator’s seat.

If you stand up, the seat switch will open. The machine will come to a standstill after 0.7 s.

NOTE: The seat switch can also open when: The operator leans out to the side and no longer has full weight on the seat.

The operator is too light. In this case, use the weight adjustment to adjust the seat.

NOTE: Always follow the stopping procedure described in this manual. Do not use the seat switch feature as a normal way to stop movement of the machine.

3-3

3 - CONTROLS AND INSTRUMENTS

Forward controls

Switches and control lamps Switch function

RAIL17COM0028FA

Beacon lamp (option) and work light (option) (1) Horn switch (2) Light switch (option) (3) Work gear and/or transportation gear switch (4) Sprinkling interval switch (5) Emergency stop (6)

1

Vibration automation switch (7) Hazard flasher switch (option) (8) Vibration selector switch (9) – front or front and rear Vibration amplitude and frequency preselect (10) Turn signal indicator switch (11) (optionl) – left or right

Beacon lamp (option) and work light (option) switch (1) Beacon lamp and the work light operation: • “0” – position 0 Both the beacon lamp and the work light are OFF. • “I” – position 1 The beacon lamp is ON. • “II” – position 2 Both the beacon lamp and the work lamp are ON. NOTE: The machine may be equipped with a beacon lamp, but the corresponding switch may not be installed. In this case, the beacon lamp operates continuously as soon as the ignition key is in position II. If the machine is no longer equipped with a beacon lamp, only the work light is illuminated.

3-4

3 - CONTROLS AND INSTRUMENTS

Push button for the horn (2) Press the button to use the horn.

Parking light and work light (3) Light switch operation: • Turn the switch to the left to turn OFF the work light.

• Turn the switch to the right to turn ON the parking light.

Work gear and transportation gear (4) The machine is equipped with two gears, high speed (rabbit) and low speed (turtle).

• Turn the switch to the left and the hydraulic drive system will switch to the “rabbit” drive position. The vibration system will not operate in this position. The machine will drive at a high speed.

• Turn the switch to the right and the hydraulic drive system will switch to the “turtle” drive position. The vibration system will operate in this position. The machine will drive at a low speed.

NOTE: The vibration system is only available in the “turtle” position.

Sprinkler interval switch (5) Continuous sprinkling • Turn the sprinkler switch from position “0” to position “1” to turn ON the sprinkler switch.

Interval sprinkling • Turn the sprinkler switch to the right past position “1” to turn ON the interval sprinkler switch.

For operation of the sprinkler see 6-3.

Emergency stop push button (6) If you get into an emergency situation that requires an immediate standstill of the machine, press the emergency stop push button on the instrument panel.

Once the emergency stop push button is pressed: • The machine will come to an immediate stop.

• The engine shuts down immediately and automatically.

• The brakes are activated.

NOTE: Only press the emergency stop push button in an emergency.

3-5

3 - CONTROLS AND INSTRUMENTS

Vibration selector switch (7) To operate in the manual vibration mode, turn the vibration selector switch to the left. Press the upper button on the travel control lever to activate the vibration.

To operate in automatic vibration mode, turn the vibration selector switch to the right. When you activate the automatic vibration and the machine reaches a speed of 1.0 – 2.0 km/h (0.6 – 1.2 mph) the machine will vibrate.

For vibration operations see 6-1.

NOTE: The minimum speed at which the machine vibrates can be changed. Contact your authorized dealer for more information.

Hazard flasher switch (8) (optional) Push the button to activate the hazard flasher.

Vibration selector switch (9) – front or front and rear Turn the vibration selector switch to the left and only the front roller will vibrate.

Turn the vibration selector switch to the right and both the front roller and the rear roller will vibrate.

Vibration amplitude and frequency preselect (10) Turn the vibration amplitude and frequency preselect switch to the left position for high frequency and low amplitude operations.

Turn the vibration amplitude and frequency preselect switch to the center position for low frequency and low amplitude operations.

Turn the vibration amplitude and frequency preselect switch to the right position for low frequency and high amplitude operations.

Turn signal indicator switch (11) (optional) Turn the indicator switch to the left or right to turn the indicator ON. Turn the switch to the center position to turn the indicator switch OFF.

3-6

3 - CONTROLS AND INSTRUMENTS

Control lamps

RAIL15COM0031FA

Engine oil pressure (1) Engine coolant temperature (2) Hydraulic oil temperature (3) Emergency stop (4) Diesel fuel reserve (5) Engine pre-heating (6)

2

Brake pressure (7) Parking lights (8) Work lights (9) Indicator control (10) Error (11) Battery charge level (12)

Engine oil pressure (1) If the lamp for the engine oil pressure illuminates during operation or if the lamp does not extinguish after start up, immediately stop the machine and turn off the engine.

• Check the engine for oil loss and for the correct level.

• If the engine oil level is correct and there is no engine oil loss, contact your authorized dealer.

3-7

3 - CONTROLS AND INSTRUMENTS

Coolant temperature lamp (2) WARNING Hot liquid under pressure!

Never remove the filler cap or the recovery tank cap while the engine is running or the coolant is hot.

Let the system cool. Loosen the recovery tank cap slowly to allow any pressure to escape.

Failure to comply could result in death or serious injury.

W1300A

NOTICE: If the coolant temperature lamp illuminates, immediately stop the machine and shut off the engine. There is a danger of the engine overheating.

If the coolant lamp illuminates during operation of the machine: 1. Immediately turn off the engine.

2. Allow the engine to cool down.

3. To avoid burns, unscrew the radiator cap one turn and allow the pressure to drop.

4. After the pressure drops, remove the radiator cap.

5. Fill with coolant.

6. Check the cooling system for leaks and the radiator and expansion vessel for the correct coolant level.

7. If you are unable to locate the error, contact your authorized dealer.

Hydraulic oil temperature (3) The hydraulic oil temperature lamp will illuminate as soon as the oil temperature exceeds 83 °C (181 °F).

Error code F32 will appear on the display screen when the oil temperature exceeds 95 °C (203 °F). In this condition, the machine can only be driven at 1.0 km/h (0.6 mph) and the vibration will not turn on. The machine will operate normally after the hydraulic oil temperature drops below 95 °C (203 °F).

Check the function of the hydraulic radiator fan and clean the heavy soiling from the radiator body.

Emergency stop (4) If the emergency stop lamp illuminates while the ignition is on: 1. Turn the emergency stop button clockwise to release the button.

2. Place the travel control lever in the neutral position.

3. Sit in the operator’s seat.

4. If the emergency stop lamp is still illuminated, contact your authorized dealer.

Diesel fuel reserve (5) The diesel fuel reserve lamp will illuminate when there is at least 30 min of remaining diesel fuel. Fill the tank with diesel fuel. See 7-8 for the tank capacity.

Engine pre-heating (6) To pre-heat the engine, hold the key in the “II” position for 15 s. Then start the engine. When you start the engine, the pre-heating lamp will turn off.

3-8

3 - CONTROLS AND INSTRUMENTS

Brake pressure (7) The brake pressure lamp will illuminate when the brake release and supply pressure of the hydraulic system are insufficient.

In this condition, the machine cannot be driven.

1. Check to see if the seat contact switch is closed.

2. Check for any display errors.

3. If the seat contact switch is closed and there are no display errors, contact your authorized dealer.

Parking lights (8) The parking light lamp illuminates and stays illuminated as long as the parking light switch is ON.

Work lights (9) The work light lamp illuminates and stays illuminated as long as the work light switch is ON.

Indicator control (10) The indicator control lamp illuminates and stays illuminated as long as the turn signal switch is ON.

Error (11) The error lamp illuminates as soon as the controller recognizes an error. At the same time, an error code will be shown on the display.

Refer to 8-1 and check the machine. If the error lamp is does not extinguish after you perform the checks, contact your authorized dealer.

Battery charge level (12) If the battery charge level lamp illuminates during operation or does not extinguish after start up, follow the procedure below: 1. Immediately stop the engine.

2. Check the engine for a defective or loose V-belt.

3. If the battery charge level lamp is still illuminated, contact your authorized dealer.

3-9

3 - CONTROLS AND INSTRUMENTS

Front controls Ignition switch • “P” – Park. In this position, you can switch ON the parking lights. The rest of the electrical loads are OFF. • “0” – OFF. All electrical loads are OFF. • “I” – Ignition. All electrical consumers are available to turn ON. • “II” – Preheat. Turn and hold the ignition key in this position for 15 s to preheat the engine.

• “III” – Start. Turn the ignition key to this position to start the engine. Release the key after the engine starts.

Speed adjusting lever The machine has one operating speed.

• Idling speed – Move the speed adjusting lever downward.

• Operating speed – Move the speed adjusting lever toward the top right.

• Check to verify that the steering works.

3-10

3 - CONTROLS AND INSTRUMENTS

Vandalism protection cover Protect against vandalism Always fold the vandalism cover back before you start the machine.

The vandalism protection cover protects the instruments from: • The effects of weather • Vandalism • Alterations by third parties

RAIL15COM0085AA

1

RAIL15COM0086AA

2

Install a padlock to secure the instrument panel from unauthorized access by third parties. There is a loop provided for this purpose.

3-11

3 - CONTROLS AND INSTRUMENTS

Left-hand side controls

Left-hand side controls (option) Two travel control levers (option) NOTE: It is only possible to drive with one travel control lever. The unused travel control lever must be in the NEUTRAL position. The vibration button and the sprinkler button are always active on both travel control levers.

To drive with the right-hand travel control lever (standard): 1. Move the left-hand travel control lever to the NEUTRAL position.

2. Drive with the right-hand travel control lever.

To drive with the left–hand travel control lever (option):

RAIL15COM0093AA

1. Move the right-hand travel control lever to the NEUTRAL position.

2. Drive with the left–hand travel control lever.

3-12

1

3 - CONTROLS AND INSTRUMENTS

Right-hand side controls

Right-hand side controls Travel control lever To drive forward: Slowly push the travel control lever forward to move the machine forward.

RAIL15COM0087AA

1

RAIL15COM0089AA

2

RAIL15COM0088AA

3

To drive in reverse: Slowly pull the travel control lever backward to move the machine in reverse.

To slow the machine down from forward or backward movement: Slowly move the travel control lever into the NEUTRAL position. The machine will hydrostatically brake automatically.

3-13

3 - CONTROLS AND INSTRUMENTS

Sprinkling (DV36 and DV45 only) Press and hold the bottom button on the travel control lever to turn the sprinkler ON. The sprinkler will stay on as long as you hold the button. For operation of the sprinkler, see 6-3.

RAIL15COM0091AA

4

RAIL15COM0091AA

5

RAIL15COM0091AA

6

Emulsion sprinkling (DV45CC only) Press and hold the bottom button on the travel control lever to turn the emulsion sprinkler ON. The emulsion sprinkler will stay on as long as you hold the button. For further information on emulsion system, see 6-4.

Vibration Press the top button on the travel control lever to turn vibration ON. Press the top button again to turn vibration OFF. See 6-1 for more procedures on vibration operations.

3-14

3 - CONTROLS AND INSTRUMENTS

Parking brake All machines are equipped with a parking brake switch.

This switch activates the parking brake. When you activate the parking brake switch, you cannot move the machine or activate vibration. The parking brake will prevent the machine from rolling on slopes.

WARNING Avoid injury and/or machine damage!

Only operate the parking brake when at a standstill. If you activate the parking brake several times while the machine is in motion, you must perform the parking brake test.

Failure to comply could result in death or serious injury.

W1404A

RAIL15COM0090AA

3-15

7

3 - CONTROLS AND INSTRUMENTS

Heated seat (option) To turn on: 1. Locate the plug for the heated seat on the right-hand side of the seat.

2. Locate the outlet on the back of the right-hand travel control lever housing. Insert the plug from the seat into the outlet.

To turn off: 1. Remove the plug for the heated seat from the outlet.

3-16

RAIL13COM0037AA

1

RAIL13COM0036AA

2

3 - CONTROLS AND INSTRUMENTS

Rearward controls

Rotating beacon (option) Beacon lamp (option) The rotating beacon attaches to the Roll Over Protective Structure (ROPS) at the rear of the machine.

NOTE: If you remove the rotating beacon, install the rubber plug.

RAIL15COM0094AA

1

RAIL15COM0095AA

2

For transportation or while the machine is not in use for extended periods of time: 1. Move the operator’s seat to the center.

2. Fold the Roller Over Protective Structure (ROPS) down.

3. Fasten the rotating beacon to the mount on the inner left-hand side of the ROPS. 4. Engage the parking brake.

3-17

3 - CONTROLS AND INSTRUMENTS

Water level gauge Locate the water level gauge on the rear left-hand side of the machine. This gauge indicates the water level in the water tank.

RAIL15COM0098AA

3-18

1

3 - CONTROLS AND INSTRUMENTS

Backup alarm The backup alarm is active as soon as the roller drives backward. The alarm stays on until the roller starts to drive forward or comes to a standstill.

3-19

3 - CONTROLS AND INSTRUMENTS

Exterior controls

Roller drum scrapers (option) Use the adjusting screws to set the contact pressure of the roller drum scraper. There is an adjusting screw on each side of the scraper bar.

• Turn the adjusting screws counter-clockwise to increase the contact pressure of the roller drum.

• Turn the adjusting screws clockwise to decrease the contact pressure of the roller drum.

RAIL13COM0038AA

3-20

1

3 - CONTROLS AND INSTRUMENTS

Battery master switch WARNING Electrical shock hazard!

Before you work on any part of the electrical system, disconnect the battery ground cable or turn the battery disconnect switch off (if equipped).

Complete all electrical work before you reconnect the cable.

Failure to comply could result in death or serious injury.

W1393A

The battery master switch disconnects the battery power supply from the battery to the machine.

Locate the battery master switch under the hood, above the battery.

RAIL15COM0118AA

1

RAIL15COM0116AA

2

RAIL15COM0117AA

3

To turn the battery master switch OFF and disconnect the power supply: Turn the red key of the battery master switch counterclockwise to the vertical position.

To turn the battery master switch ON: Turn the red key clockwise to the horizontal position.

The machine now has power.

NOTE: If you do not operate the machine for two or more days, turn the battery master switch to the OFF position.

3-21

3 - CONTROLS AND INSTRUMENTS

Display

Display screens Hour meter The actual number of operating hours of the engine displays on the screen. Perform periodic maintenance based on the engine hours.

RAIL15COM0100AA

1

RAIL15COM0102AA

2

RAIL15COM0100AA

3

Error codes When the controller recognizes an error, the error code will display on the screen. If the machine includes the optional infrared temperature sensor, the display will switch between the error code and the temperature every 5 s.

Infrared temperature sensor (option) The infrared temperature sensor measures the surface temperature. The display shows the temperature in degrees Fahrenheit.

The measured value will display when the ignition switch is in the ON position. If an error code or notice message is active, the display will switch between the error code and the temperature every 5 s.

NOTE: If the measured value deviates significantly from the expected value, clean the lens of the sensor. The sensor is on the underside of the operator’s platform. For test purposes, park the machine on a surface with a known temperature.

3-22

3 - CONTROLS AND INSTRUMENTS

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.

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.

3-23

RAIL15COM0101AA

4

3 - CONTROLS AND INSTRUMENTS

Compacting – Stiffness reference values Cold minerals To be able to evaluate the kB values, it is important to know that a sub-grade for a main road or motorway must have a stiffness value up to 100 kB • On a gravel surface, a good stiffness value will be greater than 80 kB. • For gravel layers in a pavement structure or in a frost sub-base, good stiffness values will be between 50 kB and 80 kB. • Expect stiffness values of less than 50 kB after the humus layer is removed from a clayish, very sandy, or wet ground.

Asphalt • Asphalt has a temperature-dependent stiffness. The stiffness increases as the pavement cools.

• It is important that compaction takes place only in the compactible temperature range of 140 – 80 °C (284 – 176 °F).

Regardless of the material (gravel or asphalt, the base layers or paving layers), the increase of the stiffness in kB is an important indicator for compaction tasks. As long as ACE Force detects an increase in stiffness the surface is not at its maximum compaction value. An increase in kB value is always accompanied by an increase of compaction and the load-bearing capacity.

Once you are at the maximum compaction, the kB value will no longer increase and instead have a tendency to decrease. This is the ideal moment to stop compaction. At this point, the material is at its highest possible stiffness.

3-24

4 - OPERATING INSTRUCTIONS

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

Run-in period of a new machine Do NOT load the machine at its full capacity during the first 30 h of operation for a new machine or after a major machine overhaul.

4-1

4 - OPERATING INSTRUCTIONS

Before starting the engine WARNING IMPROPER OPERATION OF THIS MACHINE CAN CAUSE DEATH OR SERIOUS INJURY. MAKE SURE THAT EVERY OPERATOR: -is instructed in the safe and proper use of this machine.

-reads and understands the operator's manual for this machine.

-reads and understands ALL safety signs on the machine.

Failure to comply could result in death or serious injury.

W0188A

WARNING Avoid injury!

Do not operate the machine while under the influence of alcohol or drugs.

Failure to comply could result in death or serious injury.

W0160A

Read the operator’s manual before you start the machine. Check daily: • Engine oil level • Hydraulic oil level • Coolant level • Fuel tank level • Water level • No loose, worn, or missing parts.

Also, before you operate the machine: • Store the articulated joint lock • Sit in the operator’s seat to activate (close) the seat switch.

• Place the travel control lever is in the NEUTRAL position • Make sure that the parking brake is OFF

4-2

4 - OPERATING INSTRUCTIONS

Starting the unit

Starting the engine WARNING Run-over hazard!

Only operate the machine when sitting in the operator’s seat. Do not try to bypass the operator presence safety system by placing heavy objects on the seat.

Failure to comply could result in death or serious injury.

W0318A

WARNING Hazard to bystanders!

Always sound the horn before starting the machine. Make sure the work area is clear of other persons, domestic animals, tools, etc. before you operate the machine. Never allow anyone in the work area during machine operation.

Failure to comply could result in death or serious injury.

W0304A

1. Fold the vandalism protection cover back.

RAIL15COM0085AA

1

RAIL15COM0091AA

2

2. Move the travel control lever into the neutral position.

4-3

4 - OPERATING INSTRUCTIONS

3. Place the speed adjusting lever into the idle position.

RAIL17COM0029AA

3

RAIL15COM0104AA

4

4. Turn the ignition key clockwise to position III. 5. As soon as the engine starts, release the ignition key.

NOTE: The control lamps for the engine oil pressure, charging, hydraulic release/supply pressure illuminate when the ignition is switched ON. Once the engine is running, the lamps will turn off.

4-4

4 - OPERATING INSTRUCTIONS

Pre-heating the system If the outside temperature is below 0 °C (32 °F): 1. Turn the ignition key to position II and hold it in this position for 15 s.

2. Turn the ignition key farther to position III to start the engine. When the engine starts, the pre-heating lamp will go out.

NOTE: In cold starting and driving conditions, the hydraulic oil will be cold. This will result in longer braking distances until the hydraulic oil reaches the normal working temperature.

4-5

4 - OPERATING INSTRUCTIONS

Assisted starting (Jump-starting) DANGER Explosion hazard!

When jump-starting the machine, connect and disconnect the jumper cables as instructed in this manual. Make sure no persons are near the connecting points before starting the engine. Start the engine from the operator’s seat.

Failure to comply will result in death or serious injury.

D0128B

WARNING Explosion hazard!

Batteries emit explosive gases. Always ventilate when using in an enclosed area or when charging.

Keep the battery away from sparks, open flames, and other ignition sources.

Failure to comply could result in death or serious injury.

W0369A

Follow the procedure below to connect the booster battery to the machine battery.

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

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

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

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

Cable connecting order 1>2>3>4.

5. Start the engine of the boost vehicle.

RAPH13CEX0080BA

6. Start the engine of the disabled machine 7. After you start the disabled machine, disconnect the booster cables exactly in the reverse order.

Cable disconnecting order 4>3>2>1.

4-6

1

4 - OPERATING INSTRUCTIONS

Stopping the unit

Stopping the engine To turn off the engine: 1. Move the travel control lever to the neutral position.

The machine will hydrostatically brake, automatically.

RAIL15COM0091AA

1

RAIL17COM0029AA

2

RAIL15COM0104AA

3

2. Move the speed adjusting lever down to the idle position.

3. Turn the ignition key to position “0” (2) and the engine will stop.

If you turn the ignition key to position “P” (1), the parking lights will turn ON. NOTE: The hazard warning light can be switched on and off independently of the ignition key position.

4-7

4 - OPERATING INSTRUCTIONS

Emergency stop If you get into an emergency situation that requires an immediate standstill of the machine, press the emergency stop push button on the instrument panel.

Once you press the emergency stop push button: • The machine will come to an immediate stop.

• The engine shuts down immediately and automatically.

• The brakes activate.

NOTE: Only press the emergency stop push button in an emergency.

To release the emergency stop: 1. Move the travel control lever to the neutral position.

2. Move the speed adjusting lever all the way back.

3. Turn the emergency stop button clockwise in the direction of the arrows until it clicks.

4. The machine is again ready for operation.

Locking brake The vibration roller is equipped with an automatic locking brake. The brakes for the drive motors activate when: • The supply pressure falls below 12 bar (174 psi) • You activate the emergency stop button.

A valve reduces supply pressure and the brakes immediately activate.

• You activate the parking brake.

A valve reduces supply pressure and the brakes immediately activate.

When you turn OFF the engine, the locking brake closes automatically.

WARNING Avoid injury and/or machine damage!

Only operate the emergency stop function when at a standstill or in an emergency. If you activate the emergency stop function several times while the machine is in motion, you must perform the parking brake test.

Failure to comply could result in death or serious injury.

W1405A

NOTICE: If the machine starts to roll on a slope, move the travel control lever in the opposite direction to keep the machine still.

4-8

RAIL17COM0030AA

4

4 - OPERATING INSTRUCTIONS

Moving the unit

Machine travel WARNING Run-over hazard!

Only operate the machine when sitting in the operator’s seat. Do not try to bypass the operator presence safety system by placing heavy objects on the seat.

Failure to comply could result in death or serious injury.

W0318A

WARNING Hazard to bystanders!

Always sound the horn before starting the machine. Make sure the work area is clear of other persons, domestic animals, tools, etc. before you operate the machine. Never allow anyone in the work area during machine operation.

Failure to comply could result in death or serious injury.

W0304A

1. Start the unit.

2. Move the speed adjusting lever up and forward to the operating speed position.

RAIL15COM0103AA

1

RAIL15COM0087AA

2

To drive forward: 3. Slowly push the travel control lever forward to move the machine forward.

4-9

4 - OPERATING INSTRUCTIONS

To drive in reverse: 4. Slowly pull the travel control lever backward to move the machine in reverse.

RAIL15COM0089AA

3

RAIL15COM0088AA

4

To slow down the machine from forward or backward movement: 5. Slowly move the travel control lever into the neutral position. The machine will hydrostatically brake, automatically.

4-10

5 - TRANSPORT OPERATIONS

5 - TRANSPORT OPERATIONS###_5_### Shipping transport

Articulated joint lock Prepare the machine for transport WARNING Transport hazard!

When you transport the machine at a work site, observe all applicable safety precautions. You must install the articulated joint lock (joint protection) before you lift the machine for transport.

Failure to comply could result in death or serious injury.

W1400A

Articulated joint lock Release the lower part of the articulated joint lock (1).

1. Remove the lock pin (2) and the lock bolt (3).

RAIL15COM0106AA

1

RAIL15COM0107AA

2

RAIL15COM0107AA

3

2. Turn the machine’s steering wheel until the articulated joint lock comes in line with the opposite loop.

3. Secure the articulated joint lock with the lock bolt (3).

4. Secure the lock bolt (3) with the lock pin (2).

5-1

5 - TRANSPORT OPERATIONS

Lifting the machine Lift the machine Lift the machine with suitable tools at the four lifting points. The four lifting points are integrated in the wheel suspension.

1. Install the articulated joint lock.

2. Lift the machine vertically with suitable hoisting equipment. Always use all four of the lifting points.

NOTE: The four lifting points have a Working Load Limit (WLL) of 5 t (11023 lb).

NOTE: The lifting devices (steel ropes, etc.) must be at least 1800 mm (71 in) long.

NOTICE: If the lifting device is not the correct length, hood damage could occur.

NOTE: If you drain the water from the tank, the machine will weigh less for transport.

5-2

RAIL15COM0108AA

1

5 - TRANSPORT OPERATIONS

Transport on a trailer Secure the machine on the trailer 1. Make sure that the articulated joint lock is in place.

2. Attach the securing straps to the tie-down points on the machine and on the trailer. Secure the machine as shown in the image to the right.

NOTE: Use a securing strap with a tensile force of 2500.0 daN (5620.2 lbf) loading capacity. The tie-down points on the machine are designed for a tensile force of 2500.0 daN (5620.2 lbf).

Angle ranges for diagonal tie down.

• 0° ≤ α ≤ 60° • 30° ≤ β ≤ 60°

RAIL15COM0151AA

1

RAIL15COM0152AA

2

RAIL15COM0111AA

3

Center of gravity The center of gravity for transport is at 710 mm (27.95 in) from the floor and at approximately the center of the machine (dependent on the fill level of the fuel tank and the water tank).

5-3

5 - TRANSPORT OPERATIONS

Roll Over Protective Structure (ROPS) Fold up/down WARNING Roll-over hazard!

A folded Roll-Over Protective Structure (ROPS) does not provide roll-over protection. Do not operate the machine with the ROPS folded as a standard operating mode. Raise the ROPS immediately after low clearance use or transport.

Failure to comply could result in death or serious injury.

W0938A

Fold ROPS down – Transport 1. Locate the Roll Over Protective Structure (ROPS) key on the left-hand side of the machine under the engine hood.

RAIL15COM0119AA

1

RAIL15COM0120AA

2

RAIL15COM0121AA

3

2. Use the ROPS key (1) to loosen the front split pins (2) on the ROPS. 3. Remove the lock pins and front split pins (2) from the left-hand and right-hand side of the ROPS.

4. Tilt the top of the ROPS slightly backwards and reinsert the split pins.

5. Lower the top of the ROPS forward onto the ROPS upright supports.

6. Install the lock pins.

5-4

5 - TRANSPORT OPERATIONS

7. Insert the ROPS key as shown.

NOTE: You may need to adjust the split pin’s position so that the ROPS key fits properly.

RAIL15COM0122AA

4

RAIL15COM0123AA

5

RAIL15COM0124AA

6

RAIL15COM0119AA

7

8. Hold the ROPS key with one hand and start to guide the top of the ROPS back past its center of gravity with your other hand.

9. Once you feel more resistance on the ROPS key, continue to lower the ROPS completely into the transport position with the ROPS key.

The ROPS in the transport position.

Fold ROPS up – For machine operation 1. Locate the Roll Over Protective Structure (ROPS) key on the left-hand side of the machine under the engine hood.

5-5

5 - TRANSPORT OPERATIONS

2. Insert the ROPS key (1) into the split pins on the ROPS (2) as shown.

NOTE: You may need to adjust the split pin’s position so that the ROPS key fits properly.

RAIL15COM0126AA

8

RAIL15COM0123AA

9

3. Maintain a secure position on the operator’s platform.

Use the ROPS key as leverage to rotate the ROPS upward.

4. Hold the ROPS in place and remove the ROPS key.

NOTE: Rotate the ROPS past its center of gravity until it safely remains in the upright position before you remove the ROPS key.

RAIL15COM0122AA

10

RAIL15COM0121AA

11

5. Remove the front split pins from the left-hand and right-hand side of the ROPS. 6. Rest the ROPS on the ROPS upright supports.

7. Lubricate the split pins.

5-6

5 - TRANSPORT OPERATIONS

8.

Insert the front split pins (2).

9.

Install the lock pins.

10. Use the ROPS key (1) to tighten the split pins (2).

NOTE: You must secure both sides of the ROPS before you operate the machine.

RAIL15COM0120AA

5-7

12

5 - TRANSPORT OPERATIONS

Recovery transport

Towing the machine Only tow the machine in an emergency in order to move the machine away from the danger zone.

• DO NOT exceed the maximum towing speed of 1.0 km/h (0.6 mph).

• DO NOT exceed the maximum towing distance of 10.0 m (32.8 ft).

• Transport the machine by truck or trailer.

Releasing the brakes Before you can tow the machine, you must release the parking brake.

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

1. Secure the machine with chocks.

2. Install the articulated joint lock. See 5-1.

RAIL15COM0112AA

1

RAIL15COM0113AA

2

RAIL15COM0114AA

3

3. Use a wrench to loosen the brake pads.

4. Open the engine hood.

5. Locate the two brake release tools in the front, righthand side of the chassis. Two M12 x 35 screws secure the brake release tools to the machine. You will use the screws as tension screws.

6. Remove the brake release tools.

7. Disconnect the battery master switch. See 3-21.

8. Remove the protective caps from the front, left-hand side drive motor and rear, right-hand side drive motor.

5-8

5 - TRANSPORT OPERATIONS

9.

Attach the brake release tool to the front, left-hand side drive motor with one of the tension screws by hand.

10. Turn the wrench approximately one-half turn downward. The wrench rotation on the motor is approximately 180° 11. Follow the same procedure on the on the rear, righthand side drive motor.

12. Remove the chocks. You can now tow the machine.

RAIL15COM0115AA

4

RAIL15COM0112AA

5

RAIL15COM0115AA

6

RAIL15COM0113AA

7

After you tow the machine: 1. Secure the machine with chocks.

2. Tighten the brakes on the front, left-hand side drive motor and the rear, right-hand side drive motor.

3. Install the protective caps to the front, left-hand side drive motor and the rear, right-hand side drive motor.

4. Stow the brake release tools.

5. Connect the battery master switch. See 3-21.

6. Stow the articulated joint lock. See 5-1.

7. Close the engine hood.

8. Remove the chocks. The machine is now ready to operate.

5-9

5 - TRANSPORT OPERATIONS

5-10

6 - WORKING OPERATIONS

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

Vibration operation Single and double vibration To avoid damage to material due to harsh vibration movement: • Never use vibration while idling.

• Never use vibration while at a standstill.

• Only switch vibration on if the speed adjusting lever is set to an operating speed.

Preselecting the frequency • Turn the vibration amplitude and frequency preselect switch to the left position for high frequency and low amplitude operations.

• Turn the vibration amplitude and frequency preselect switch to the center position for low frequency and low amplitude operations.

• Turn the vibration amplitude and frequency preselect switch to the right position for low frequency and high amplitude operations.

RAIL15COM0128AA

1

RAIL15COM0129AA

2

RAIL15COM0130AA

3

Vibration ON/OFF • Turn the switch to the left and only the front roller will vibrate.

• Turn the switch to the right and both the front and the rear roller will vibrate.

NOTE: When you switch from double vibration to single vibration, expect a brief interruption of the vibration.

Manual vibration 1. Set the vibration preselect switch to the “Manual” position.

6-1

6 - WORKING OPERATIONS

2. Press the vibration button once on the travel control lever and the roller(s) will vibrate.

3. Press the vibration button on the travel control lever again and the vibration of the roller(s) will turn OFF. NOTE: In the manual vibration mode, the roller(s) will vibrate as soon as you press the vibration button on the travel control lever while you are in motion or at a standstill.

RAIL15COM0091AA

4

RAIL15COM0131AA

5

Automatic vibration 1. Set the vibration preselect switch to the “Auto” position. .

2. Press the vibration button the travel control lever.

Vibration will switch ON at speeds greater than 1.0 – 2.0 km/h (0.6 – 1.2 mph) and switches off at speeds less than 1.0 – 2.0 km/h (0.6 – 1.2 mph) 3. Vibration is not possible with the roller at a standstill.

6-2

6 - WORKING OPERATIONS

Sprinkling Continuous sprinkling Turn the sprinkler switch from position “0” to position “1” to turn ON the sprinkler switch.

The sprinkler switches ON.

RAIL15COM0132AA

1

RAIL15COM0132AA

2

Intermittent sprinkling Turn the sprinkler to the right past position “1” to turn ON the interval sprinkler switch.

Interval between sprinkler spray

Graduation marks 1 2 3 4 5

1s 5s 10 s 15 s 20 s

6-3

6 - WORKING OPERATIONS

Emulsion sprinkling (DV45CC) Emulsion sprinkling applies separation emulsion (anti-adhesive agent) to the machine tires. This separation emulsion ensures effective separation of the tires and the compacted surface.

Advantages of the use of an anti-adhesive agent: • There are no trails on the compacted surface thanks to the effective separation effect.

• Extremely low consumption of the anti-adhesive agent.

• The surface can be processed at higher temperatures.

• The surface does not suffer from the rolling so much thanks to the lower water consumption.

• The anti-adhesive agent does not cause deterioration of the rubber tires.

• The penetration of excessive anti-adhesive agent does not have any other negative effects.

• The anti-adhesive agent is biologically degradable.

Emulsion filler neck The emulsion tank filler neck is located on the left-hand side of the driver’s position under the cover in the foot plate.

RAIL17COM0001AA

1

RAIL15COM0091AA

2

Emulsion sprinkling Press and hold the bottom button on the travel control lever to turn the emulsion sprinkler ON. The emulsion sprinkler will stay on as long as you hold the button.

6-4

7 - MAINTENANCE

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

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

Torque charts Regularly check the bolt connections and confirm that they have not loosened.

Use torque wrenches to tighten the bolts.

Hex screws and hex socket screws (Allen) Hex 10 13 13 15 17 19 19 19 24 24 30 30

Allen 5 6 — — — 10 — — — — — —

Screw diameter M6 M8 M8 M10 x 1.25 M10 M12 M12 M14.5 x 1.5 M16 M16 M20 M20

Bolt class 8.8 8.8 10.9 10.9 8.8 8.8 10.9 10.9 8.8 10.9 8.8 10.9

Tightening torque 10 N·m (7.38 lb ft) 25 N·m (18.44 lb ft) 36 N·m (26.55 lb ft) 75 N·m (55.32 lb ft) 48 N·m (35.40 lb ft) 84 N·m (61.96 lb ft) 123 N·m (90.72 lb ft) 209 N·m (154.15 lb ft) 206 N·m (151.94 lb ft) 302 N·m (222.74 lb ft) 415 N·m (306.09 lb ft) 592 N·m (436.64 lb ft)

Low-profile cylinder head screws and oval head screws Allen 3 5 5

Screw diameter M5 M8 M10

Bolt class 10.9 10.9 10.9

Tightening torque 4 N·m (2.95 lb ft) 10 N·m (7.38 lb ft) 18 N·m (13.28 lb ft)

Screw diameter M10

Bolt class 12.9

Tightening torque 40 N·m (29.50 lb ft)

Screw diameter M10

Bolt class 12.9

Tightening torque 40 N·m (29.50 lb ft)

Allen 5 10 —

Screw diameter 1/8” thread 1/2” thread M22 x 1.5

Tightening torque 13 N·m (9.59 lb ft) 80 N·m (59.00 lb ft) 90 N·m (66.38 lb ft)

Shoulder screws Allen 6 Countersunk head screws Allen 6 Screw plugs Hex — — 27

7-1

7 - MAINTENANCE

Drain valve Drain valve Diesel fuel tank Hydraulic tank

Tightening torque Secure the screw connections with universal pipe sealant and tighten by hand, not with torque.

Secure the screw connections with universal pipe sealant and tighten by hand, not with torque.

7-2

7 - MAINTENANCE

Recommended engine oil for operating temperature ranges CJ-4 Oils

(H)

0W-40 CJ-4 UNITEK to MAT3521

(H)

API CJ–4 0W-40 (H)

10W-40 CJ-4 UNITEK to CNH MAT3521

(H)

API CJ–4 10W-40 (H)

15W-40 CJ-4 UNITEK to CNH MAT3521

(H)

-40 °C -40 °F

-30 °C -22 °F

-20 °C -4 °F

-10 °C 14 °F

API CJ–4 15W-40

0 °C 32 °F

10 °C 50 °F

(H) Engine oil pan or coolant block heater recommended in this range

7-3

20 °C 68 °F

30 °C 86 °F

40 °C 104 °F

50 °C 122 °F

7 - MAINTENANCE

Opening the hood WARNING Rotating parts!

Shut off the engine before opening the engine hood.

Failure to comply could result in death or serious injury.

W1059A

WARNING Burn hazard!

The engine and exhaust system become hot during operation. To prevent burns, open the engine compartment and allow the components to cool to a comfortable touch temperature before you work inside the engine compartment.

Failure to comply could result in death or serious injury.

W1406A

There is one locking device on each side of the engine hood.

1. Open both latches.

2. Locate the handle on the left-hand side of the engine hood.

3. With the handle, lift the engine hood with slight pressure toward the center of the machine.

RAIL15COM0219AA

1

RAIL15COM0220AA

2

To secure the engine compartment from unauthorized access, install a padlock through the provided loops.

NOTE: Two gas absorbers 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 absorbers.

7-4

7 - MAINTENANCE

Biodiesel fuel - Biodiesel fuels Biodiesel fuel usage in CASE CONSTRUC- • ASTM D975, Standard Specification for Diesel Fuel Oils. ( 15 ppm sulfur maximum.)

TION products The following standards apply to biodiesel fuel blends:

Introduction to biodiesel fuel Fatty Acid Methyl Ester (FAME) biodiesel fuel, called biodiesel fuel in the following paragraphs, consists of a family of fuels derived from vegetable oils that producers treat with methyl esters.

There are two main biodiesel fuel types: Rapeseed Methyl Ester (RME) and Soybean Methyl Ester (SME).

RME is a blend of rapeseed and sunflower methyl ester. RME is the preferred crop in Europe. SME is the preferred crop in the United States.

Biodiesel fuel is a renewable alternative fuel source. Its use and development is promoted worldwide, especially in Europe and in the United States.

NOTICE: It is imperative that you check with your CASE CONSTRUCTION dealer to learn which biodiesel fuel blend CASE CONSTRUCTION approves for use in your engine. Be aware that the use of biodiesel fuel blends that do not comply with ASTM D6751 could cause severe damage to the engine and fuel system of your machine.

The use of non-approved biodiesel fuel blends may void CASE CONSTRUCTION Warranty coverage.

Biodiesel fuel blends use the following labels to indicate the percentage of biodiesel fuel in the blend: • B5: indicates the blend of 5% biodiesel fuel and 95% diesel fuel.

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

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

• B100: indicates 100% biodiesel fuel.

Biodiesel fuel has several positive features in comparison with diesel fuel: • Biodiesel fuel adds lubricity to the fuel. Additional lubricity is beneficial in many circumstances, particularly as fuels contain less sulfur and aromatics.

• Biodiesel fuel has a greater cetane number and burns more cleanly.

• Biodiesel fuel produces less particulate matter and reduces smoke emissions.

• Biodiesel fuel is fully biodegradable and non-toxic.

Specifications for diesel fuel and biodiesel fuel The following standards apply to diesel fuel specifications:

• United States Diesel Fuel Specification ASTM D6751 allows up to 5% biodiesel since 2009. United States fuel suppliers are allowed to use up to 5% biodiesel fuel (B5) to supply the network.

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

The following standards apply to pure biodiesel fuel (B100): • ASTM D6751 - Standard specification for biodiesel fuel blend stock (B100) for middle distillate fuels.

NOTE: ASTM updated ASTM D6751 to improve the quality of biodiesel in the market place.

Before producers can convert raw oil into usable biodiesel fuel, it must undergo transesterification to remove glycerides. During the transesterification process, the oil reacts with an alcohol to separate the glycerin from the fat or vegetable oil. This process leaves behind two products: methyl ester (the chemical name for biodiesel) and glycerin (a byproduct usually sold for use in soaps or other products).

NOTICE: CASE CONSTRUCTION only approves transesterified biodiesel fuel blends that comply with ASTM D6751.

NOTICE: Non-transesterified fuels made from rapeseed oil or similar high oil content crops include cold-pressed biodiesel, cold-pressed oil, Straight Vegetable Oil (SVO), or more generally unrefined vegetable oils used as motor fuel. Because these types of fuel are not transesterified, they do not fulfil the requirements of ASTM D6751. There is no recognized quality standard available for these types of fuel; therefore, CASE CONSTRUCTION DOES NOT APPROVE the use of cold-pressed biodiesel, cold-pressed oil, Straight Vegetable Oil (SVO), or more generally unrefined vegetable oils as motor fuel at any blend in any CASE CONSTRUCTION product.

NOTICE: CASE CONSTRUCTION will discontinue Warranty coverage of any engine equipment and fuel injection equipment you fit to a CASE CONSTRUCTION machine that is found to have run with blend of NON-APPROVED fuel (fuel that does not fulfill the requirements of ASTM D6751).

Biodiesel fuel usage conditions You must stringently follow the biodiesel fuel usage conditions. Incorrect application of the biodiesel fuel usage conditions could lead to severe damage to the engine and fuel injection equipment and aftertreatment system.

7-5

7 - MAINTENANCE

The main concerns about operation of equipment with biodiesel fuels are:

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

• Filter and injector blockage caused by poor fuel quality • Wear and corrosion of internal components due to water content, which affects lubricity • Deterioration of some rubber sealing compounds in the fuel system • Biodiesel oxidation, which can lead to the formation of deposits that may harm the fuel injection system NOTICE: CASE CONSTRUCTION Warranty will not cover any problem in the engine fuel injection equipment that results from non-compliance with the following conditions for biodiesel fuel handling and biodiesel fuel maintenance.

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

The supplier must pre-blend biodiesel fuel. Mixing biodiesel fuel blends on-site can result in an incorrect mixture that may damage the engine and/or fuel system.

For machines using Tier 4A (interim) and Stage IIIB engines with an exhaust aftertreatment system, the use of biodiesel blends above B5 through B20 will not void the CASE CONSTRUCTION warranty as long as you stringently follow these conditions for biodiesel fuel handling and maintenance:

NOTICE: CASE CONSTRUCTION may void your warranty if the problem is associated with poor fuel quality due to improper blending. It is the responsibility of the fuel supplier and/or yourself to ensure the right type of fuel and blend is delivered and used.

Maintenance intervals For machines using the all-electronic engines with a highpressure common rail fuel system, the use of biodiesel blends up to B20 reduces the engine oil and filter change interval to 250 h. For all engines, see the operator’s manual for specific maintenance intervals.

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

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

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

1. If you use a biodiesel blend stock to ASTM D6751, you must take special precautions. Ensure that the biodiesel blend stock fully complies with the following special requirements: • Group I Metals content (sodium and potassium) must be less than or equal to 5 mg/kg per EN14538.

• Group II Metals content (calcium and magnesium) must be less than or equal to 5 mg/kg per EN14538.

• Phosphorus content lower than 4 mg/kg is a mandatory requirement (per ASTM D4951).

2. The resulting greater than B5 through B20 blend must not exceed 1 mg/kg for Group I Metals (sodium and potassium) and for Group II Metals (calcium and magnesium).

When switching back from biodiesel to regular #2 diesel, you should change all fuel filters, oil and oil filter even if the changeover falls between routine service intervals.

Storage You should not store the machine for more than three months with biodiesel fuel in the fuel system. For longer storage time, CASE CONSTRUCTION strongly suggests that you use only regular #2 diesel fuel.

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

Biodiesel fuel is highly hygroscopic and tends to collect water more than diesel fuel. Water collection increases the risk of algae and bacteria growth that can cause severe damage to the fuel injection system. Keep the machine fuel tanks and on-site storage tanks as full as possible to limit the amount of air and water vapor inside. Drain water from the tanks at least once a week.

NOTICE: Use only CASE CONSTRUCTION approved biocide additives.

7-6

7 - MAINTENANCE

Diesel fuel - Diesel fuel Only use diesel fuel that conforms to North American standard ASTM D975 Grade No. 2-D S15 or equivalent in your engine. Do not use any other low grade diesel fuel.

NOTE: When operating the machine in very cold climates, the use of winter blended fuel is permitted for a short period of time. See your fuel supplier for winter fuel requirements in your area.

NOTICE: Use of other low grade diesel fuels will result in loss of engine power, high fuel consumption, and damage to the exhaust aftertreatment system (if equipped).

Fuel conditioner Diesel fuel conditioner is available from your CASE CONSTRUCTION dealer. Instructions for the use of the fuel conditioner is on the container.

The use of diesel fuel conditioner will: • Clean fuel injectors, valves, and manifolds for increased service life

• Separate moisture from the fuel • Stabilize fuel in storage NOTICE: Use only CASE CONSTRUCTION approved biocide additives to prevent damage to the exhaust aftertreatment system (if equipped).

• Disperse insoluble gummy deposits that form in the fuel system

7-7

7 - MAINTENANCE

Consumables and 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)

7-8

7 - MAINTENANCE

Maintenance planning

Maintenance chart Grease Test Replace Check

Cleaning Drain fluid Filling

Maintenance action Every 10 hours of operation or daily x 7-11 Fuel level - Check x 7-12 Engine oil level - Check x 7-13 Hydraulic oil level - Check x 7-15 Engine coolant level - Check x 7-16 Sprinkler system - Check x 7-17 Roller drum scrapers - Check x 7-18 Air intake - Check x 7-18 Fuel filter water separator - Check x 7-19 Air filter service indicator x 7-19 Battery charge - Check x Water level indicator 7-20 x 7-21 Tire pressure (DV45CC) x 7-21 Emulsion level (DV45CC) Initial 50 hours x 7-22 Engine oil and filter (Initial) Every 50 hours or weekly x Brakes 7-24 x 7-25 Air filter vacuum valve x 7-26 Seat switch and emergency stop Every 100 hours or monthly x 7-27 Steering cylinder Initial 250 hours x 7-22 Engine oil and filter (Initial) Initial 500 hours x 7-30 Ventilation filter for the hydraulic oil tank x 7-31 Hydraulic oil and filter Every 500 hours of operation or every 6 months x 7-35 Fuel filter x 7-37 Clean the fuel filter water separator x 7-38 Engine air filter - Replace x 7-40 Engine oil and filter Every 1000 hours or annually x 7-30 Ventilation filter for the hydraulic oil tank x 7-31 Hydraulic oil and filter x Fuel tank sediment 7-47 x Articulated joint pivot 7-48 x Pendulum joint 7-49 As required x Fuel tank 7-50 x 7-31 Hydraulic oil and filter x 7-55 Hydraulic oil cooler x Radiator 7-56 x 7-57 Cleaning the machine x Battery 7-58 x Articulated joint pivot 7-48 x Pendulum joint 7-49 7-9

Page no.

7 - MAINTENANCE

Grease Test Replace Check Maintenance action Front work lights and parking lights (optional) Turn signal and flasher bulb (Optional) Rear work light and tail lights (optional) Rotating beacon light (optional) Water tank and sprinkler - Drain Water tank - Fill Sprinkler nozzles Pneumatic wheel scrapers (DV45CC)

Cleaning Drain fluid Filling Page no.

x x x x x x x x

7-10

7-63 7-64 7-65 7-66 7-68 7-70 7-70 7-70

7 - MAINTENANCE

Every 10 hours of operation or daily

Fuel level - Check WARNING Fuel vapors are explosive and flammable.

Do not smoke while handling fuel. Keep fuel away from flames or sparks. Shut off engine and remove key before servicing. Always work in a well-ventilated area. Clean up spilled fuel immediately.

Failure to comply could result in death or serious injury.

W0904A

WARNING Fire hazard!

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

Fuel combinations may increase fire and explosion hazards.

Failure to comply could result in death or serious injury.

W0401A

Check the fuel level every 10 hours or daily.

Type of fuel

Capacity

Service specifications Use fuel that complies with the American Society for Testing and Materials (ASTM) D975 standard.

Grade number 2 diesel fuel 40 L (15.59 US gal)

When the control lamp for the diesel fuel tank illuminates for the first time, you have at least 30 min of remaining fuel.

RAIL15COM0133AA

1

RAIL15COM0134AA

2

Fueling Fill the tank with diesel fuel up to the lower edge of the filler neck • Every day before you begin work operations, or • As soon as the control lamp for the diesel fuel illuminates.

7-11

7 - MAINTENANCE

Engine oil level - Check The engine oil level should be checked every 10 hours of operation or daily.

Type of oil Capacity

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

NOTICE: DO NOT run the engine unless it has the correct level of engine oil. After the engine stops, wait 3 min to allow for the engine oil to drain to the sump before you check the oil level.

1.

Locate the engine oil dipstick on the left-hand side of the machine.

2.

Remove the engine oil dipstick and check the engine oil level.

RAIL15COM0135AA

1

RAIL15COM0136AA

2

RAIL15COM0138AA

3

3. Make sure that the engine oil level is between the “H” and the “L” marks.

4. If necessary, add engine oil.

5. Fill at either the filler neck (2) on the left-hand side of the engine or at the filler neck (1) on the engine.

NOTE: After you refill the engine oil, wait 3 min to allow the oil to drain to the sump before you check the oil level.

7-12

7 - MAINTENANCE

Hydraulic oil level - Check Check the hydraulic oil level every 10 hours or daily.

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

NOTICE: Use of 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 machine that runs on synthetic ester HE need replacement, only use hoses that are compatible with synthetic esters as declared by the supplier.

NOTICE: Always consult with your authorized dealer before you switch from mineral oil to synthetic oil or mix oils from different brands.

Type of hydraulic oil Capacity

Service specifications CASE AKCELA NEXPLORE™ FLUID 37.0 L (9.77 US gal)

Always check the hydraulic oil level at operating temperature with a running engine.

1.

Park the machine on level ground.

2.

Continue to let the machine idle.

3.

On the left-hand side of the machine, check the hydraulic oil level in the inspection window.

NOTE: The hydraulic oil level must always be visible in the oil gauge. If there is a significant loss of oil, determine the cause of the hydraulic system leak. These could be leaks through the hose screw joints, screwed fitting of the hydroelectric generators, or of the hydraulic motors, etc. Repair the defects.

RAIL15COM0137AA

1

RAIL15COM0139AA

2

4. If the oil level is within the lower third of the inspection window, then add hydraulic oil through the filler neck.

5. Remove the cap on the filler neck to the hydraulic oil tank.

7-13

7 - MAINTENANCE

6. Fill with hydraulic oil.

RAIL15COM0140AA

3

RAIL15COM0141AA

4

7. Install the cap to the hydraulic oil tank.

NOTE: Before you install the hydraulic oil cap, always grease the O-ring.

7-14

7 - MAINTENANCE

Engine coolant level - Check WARNING Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in death or serious injury.

W0330B

Check the coolant reservoir level every 10 hours of operation or daily.

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

NOTICE: Never use a coolant concentration over 68% Type of coolant Capacity

Service specifications CNH XHD HEAVY DUTY COOLANT / ANTI-FREEZE —

1. Park the machine on a level surface and make sure the engine is cold.

2. Check the coolant level on the expansion tank display.

The coolant level must between the top mark (FULL) and the bottom mark (LOW).

RAIL15COM0142AA

1

RAIL15COM0143AA

2

3. If necessary, add coolant.

4. Unscrew the tank lid of the radiator.

5. Add coolant with anti-freeze until the tank is full.

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.

7-15

7 - MAINTENANCE

Sprinkler system - Check Check the sprinkler system every 10 hours of operation or daily.

1. Turn the sprinkler ON.

RAIL15COM0132AA

1

RAIL15COM0144AA

2

2. Check the nozzles on the sprinkler tubes in the front and the back.

3. If it is necessary to clean the sprinkler, see page 7-70.

7-16

7 - MAINTENANCE

Roller drum scrapers - Check Check the front and rear roller drum scrapers every 10 hours of operation or daily.

After a blade replacement, correctly set the height of the scraper.

Make sure that the contact pressures of the roller drum scrapers are set correctly to ensure proper cleaning of the drum while the machine operates.

1. Adjust the mounting screws to set the height of the new scraper blade.

RAIL15COM0144AA

1

RAIL13COM0038AA

2

2. Gently adjust the contact pressure of the roller drum scrapers.

3. Turn the adjusting screws counter-clockwise to increase the contact pressure of the roller drum.

4. Turn the adjusting screws clockwise to decrease the contact pressure of the roller drum.

7-17

7 - MAINTENANCE

Air intake - Check Check the air intake every 10 hours of operation or daily.

1. Check the air intake for dirt.

2. If necessary, clean the air intake.

RAIL15COM0145AA

1

Fuel filter water separator - Check WARNING Fire hazard!

When handling diesel fuel, observe the following precautions: 1. Do not smoke.

2. Never fill the tank when the engine is running.

3. Wipe up spilled fuel immediately.

Failure to comply could result in death or serious injury.

W0099A

Check the fuel filter water separator every 10 hours of operation or daily.

1. Check the fuel filter water separator filter element.

2. If the red float ring rises, drain the water from the housing.

3. Use a suitable container to collect the water.

4. Open the drain fitting and drain the water until clean fuel flows. Do not allow fuel to spill on the engine or the ground.

5. Close the drain fitting.

RAIL15COM0146AA

7-18

1

7 - MAINTENANCE

Air filter service indicator Check the air filter service indicator every 10 hours of operation or daily.

If a red ring appears on the air filter indicator when you turn on the engine, you must inspect the air filter cartridge.

If there is damage, replace the air filter cartridge. See 7-38 for the air filter cartridge replacement procedures.

If the air filter cartridge is dirty but there is no damage, clean the air filter cartridge. See 7-38 for the air filter cleaning procedures.

RAIL15COM0147AA

1

NOTE: Clean the outer air filter cartridge a maximum of six times. After that, replace the outer air filter cartridge.

Battery charge - Check Read the battery charge level on the display screen.

• When you turn the ignition ON the battery voltage displays. During start-up of the machine, the battery voltage should not drop below 10 V. If the voltage drops below 10 V, charge the battery.

• After start-up, the alternator charging voltage displays. The voltage should display between 13 – 14.5 V

RAIL15COM0148AA

7-19

1

7 - MAINTENANCE

Water level indicator 1. Locate the water level indicator at the rear left-hand side of the machine.

RAIL15COM0098AA

1

RAIL15COM0162AA

2

2. Read the water level.

• If the water level indicator displays a full tank (1), you can turn on the sprinkling system.

• If the water level indicator displays an empty tank (2), fill the tank with clean water before you turn on the sprinkler system.

7-20

7 - MAINTENANCE

Tire pressure (DV45CC)

RAIL17COM0004EA

1. Tire pressure OK

2. Tire pressure too low

1

3. Tire pressure too high

1. Check the tire pressure as required. The tire pressure should be approximately 1.0 bar (14.5 psi) but should be adjusted to suit the compaction condition of the ground.

NOTICE: The tires must be replaced if the fabric is visible on the tire surface.

2. The two tires on each side are connected to each other.

The valves for inflating the tires come through the same opening. Valve (4) is to the inner tire, valve (5) is for the outer tire.

RAIL17COM0006AA

2

RAIL17COM0001AA

1

Emulsion level (DV45CC) 1. Check and fill as necessary the emulsion tank.

7-21

7 - MAINTENANCE

Initial 50 hours

Engine oil and filter (Initial) WARNING Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in death or serious injury.

W0330B

Drain the engine oil and replace the engine oil filter after the first 50 hours and first 250 hours for a new machine.

After the initial 50-hour and 250-hour services, drain the engine oil and replace the engine oil filter every 500 hours or six months, or as required.

Type of oil Capacity

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

Drain the engine oil 1. Locate the engine oil drain on the left-hand side of the machine between the front chassis and rear chassis.

2. Turn the machine all the way to the right. This will provide easy access to the engine oil drain.

3. Place a suitable container under the engine oil drain.

RAIL15COM0187AA

1

RAIL15COM0188AA

2

4. Turn the engine oil drain plug counter-clockwise to drain the engine oil. Engine oil will immediately start to flow.

NOTE: Drain the engine oil when it is warm. Warm oil (not hot) will flow faster.

5. Turn the engine oil drain plug clockwise to close the engine oil drain. Torque the engine oil drain plug to: 54.2 – 63.7 N·m (40.0 – 47.0 lb ft).

NOTICE: Dispose of all fluids filters, and containers in an environmentally safe manner and in accordance with local laws and regulations. Check with local environmental and recycling centers or your dealer for correct disposal information.

7-22

7 - MAINTENANCE

Replace the engine oil filter 6. Open the engine hood.

7. Place a rag under the engine oil filter to collect oil once you remove the filter.

8. Remove the engine oil filter with a filter wrench or by hand.

RAIL15COM0167AA

3

RAIL15COM0189AA

4

RAIL15COM0156AA

5

9. Dispose of the filter and collected oil in accordance with local, regional, and federal regulations.

10. Use a clean cloth and wipe the sealing surface of the oil filter base to remove all dirt.

11. Apply a thin layer of engine oil to the gasket of the new oil filter.

12. Turn the new oil filter onto the base until the gasket makes contact with the base.

13. Torque the engine oil filter to: 19.0 – 23.0 N·m (14.0 – 17.0 lb ft) or use the filter wrench to turn the engine oil filter one additional turn.

NOTICE: Only use genuine, specified filters.

Fill the engine oil tank 14. Fill at either the filler neck (2) on the left-hand side of the engine or at the filler neck (1) on the engine.

NOTE: After you refill the engine oil, wait 5 min to allow the oil to drain to the sump before you check the oil level.

15. Close the engine hood.

7-23

7 - MAINTENANCE

Every 50 hours or weekly

Brakes WARNING Avoid injury and/or machine damage!

Only operate the parking brake when at a standstill. If you activate the parking brake several times while the machine is in motion, you must perform the parking brake test.

Failure to comply could result in death or serious injury.

W1404A

Test the brakes every 50 hours of operation or weekly.

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

RAIL15COM0163AA

1

RAIL15COM0164AA

2

2. Seal the open end of the brake hose. This allows the brake hose to pressurize.

3. Start the machine.

4. Press the parking brake switch. The parking brake lamp must quickly go out.

5.

Move the travel control lever forward and backward. The machine should not move.

NOTE: Since the front brake stays activated, the machine will not move.

6.

Turn the machine off.

7.

Install the brake hose to the front roller drum.

8.

Follow the same test procedure for the rear drive motor.

9.

Make sure all brake lines are connected.

10. Start the machine.

11. The parking brake lamp must quickly extinguish.

12. Move the travel control lever forward and backward. The machine should not move.

NOTICE: If at any time during the brake test the machine does not operate exactly as described, you have a problem with one or more of the brakes. Do not operate the machine as damage to property could occur. Contact your authorized dealer for repair.

7-24

7 - MAINTENANCE

Air filter vacuum valve Check the air filter vacuum valve every 50 hours of operation or weekly.

1. To clean the air filter vacuum valve, press and release any trapped dust.

NOTE: When the machine is running, any trapped dust in the air filter vacuum valve is automatically emptied.

NOTICE: DO NOT operate the machine with a damaged air filter vacuum valve. If the air filter vacuum valve is damaged, replace the valve with a new one.

RAIL15COM0165AA

7-25

1

7 - MAINTENANCE

Seat switch and emergency stop Test the seat switch and the emergency stop every 50 hours of operation or weekly.

1. Move the travel control lever into the NEUTRAL position.

2. Sit in the operator’s seat.

3. Start the engine. The parking brake lamp must quickly extinguish.

4. Leave the operator’s seat. After 0.7 s, the parking brake lamp must illuminate.

5. Turn off the engine.

NOTE: The emergency stop lamp only illuminates when you press the emergency stop switch.

NOTE: The lamps for the emergency stop switch, the neutral position for the travel control lever, and the seat contact switch must turn off after 2 s of delayed seat contact.

7-26

7 - MAINTENANCE

Every 100 hours or monthly

Steering cylinder Grease the steering cylinder every 100 hours of operation or monthly.

Type of grease

Service specifications CASE AKCELA 251H EP MULTI-PURPOSE GREASE

1. Rotate the machine’s steering wheel fully to the stop in order to grease the cylinder.

2. Steer the machine to the right and to the left. This will unload the bearing.

3. Remove the protective covers from the grease points.

4. Clean the grease points.

5. Apply grease to the two grease points until grease appears.

6. Install the protective covers on the grease points.

RAIL15COM0166AA

1

NOTICE: Avoid damage due to increased wear. Grease the steering cylinder after every cleaning or steam cleaning of the machine.

Initial 250 hours

Engine oil and filter (Initial) WARNING Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in death or serious injury.

W0330B

Drain the engine oil and replace the engine oil filter after the first 50 hours and first 250 hours for a new machine.

After the initial 50-hour and 250-hour services, drain the engine oil and replace the engine oil filter every 500 hours or six months, or as required.

Type of oil Capacity

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

7-27

7 - MAINTENANCE

Drain the engine oil 1. Locate the engine oil drain on the left-hand side of the machine between the front chassis and rear chassis.

2. Turn the machine all the way to the right. This will provide easy access to the engine oil drain.

3. Place a suitable container under the engine oil drain.

RAIL15COM0187AA

1

RAIL15COM0188AA

2

4. Turn the engine oil drain plug counter-clockwise to drain the engine oil. Engine oil will immediately start to flow.

NOTE: Drain the engine oil when it is warm. Warm oil (not hot) will flow faster.

5. Turn the engine oil drain plug clockwise to close the engine oil drain. Torque the engine oil drain plug to: 54.2 – 63.7 N·m (40.0 – 47.0 lb ft).

NOTICE: Dispose of all fluids filters, and containers in an environmentally safe manner and in accordance with local laws and regulations. Check with local environmental and recycling centers or your dealer for correct disposal information.

Replace the engine oil filter 6. Open the engine hood.

7. Place a rag under the engine oil filter to collect oil once you remove the filter.

8. Remove the engine oil filter with a filter wrench or by hand.

RAIL15COM0167AA

9. Dispose of the filter and collected oil in accordance with local, regional, and federal regulations.

10. Use a clean cloth and wipe the sealing surface of the oil filter base to remove all dirt.

11. Apply a thin layer of engine oil to the gasket of the new oil filter.

7-28

3

7 - MAINTENANCE

12. Turn the new oil filter onto the base until the gasket makes contact with the base.

13. Torque the engine oil filter to: 19.0 – 23.0 N·m (14.0 – 17.0 lb ft) or use the filter wrench to turn the engine oil filter one additional turn.

NOTICE: Only use genuine, specified filters.

RAIL15COM0189AA

4

RAIL15COM0156AA

5

Fill the engine oil tank 14. Fill at either the filler neck (2) on the left-hand side of the engine or at the filler neck (1) on the engine.

NOTE: After you refill the engine oil, wait 5 min to allow the oil to drain to the sump before you check the oil level.

15. Close the engine hood.

7-29

7 - MAINTENANCE

Initial 500 hours

Ventilation filter for the hydraulic oil tank WARNING Chemical hazard!

When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.

Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals.

Failure to comply could result in death or serious injury.

W0371A

Replace the ventilation filter for the hydraulic oil tank after the first 500 hours of operation for a new machine. Then replace the ventilation filter at every 1000 hours of operation or annually.

The hydraulic oil fill cap is also a ventilation filter for the hydraulic oil tank.

1. Open the engine hood.

2. Remove the ventilation filter.

3. Replace the ventilation filter with a new filter.

4. Grease the O-ring of the new ventilation filter.

5. Close the engine hood.

RAIL15COM0176AA

7-30

1

7 - MAINTENANCE

Hydraulic oil and filter WARNING Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in death or serious injury.

W0330B

WARNING Pressurized system!

Never attempt to drain fluids or remove filters when the engine is running. Turn off the engine and relieve all pressure from pressurized systems before servicing the machine.

Failure to comply could result in death or serious injury.

W0905A

Drain the hydraulic oil and replace the hydraulic oil filter after the first 500 hours of operation for a new machine.

After the first 500 hours of operation, drain the hydraulic oil and replace the hydraulic oil filter at every 1000 hours of operation or annually, or as required.

Type of hydraulic oil Capacity

Service specifications CASE AKCELA NEXPLORE™ FLUID 37.0 L (9.77 US gal)

NOTICE: Always consult with your authorized dealer before you switch from mineral oil to synthetic oil or mix oils from different brands.

Drain the hydraulic oil 1. Place a suitable container (minimum 30.0 L (7.9 US gal) capacity) under the hydraulic oil drain.

RAIL15COM0178AA

1

RAIL15COM0179AA

2

2. Remove the hydraulic oil tank cap.

7-31

7 - MAINTENANCE

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

NOTE: Drain the hydraulic oil when the oil is still warm, but not hot. The oil will flow more easily.

4. Secure the screw connections with LOCTITE® 242® Hand-tighten the screw connections. Do not torque the screw connections. See 7-1.

RAIL15COM0178AA

3

NOTE: Replace the hydraulic oil filter whenever you drain the hydraulic oil. Replace the hydraulic oil filter before you fill the hydraulic tank with new oil.

Replace the hydraulic oil filter 5. Remove the hydraulic oil tank cap.

RAIL15COM0180AA

4

RAIL15COM0181AA

5

RAIL15COM0182AA

6

6. Unlock the hydraulic oil filter element.

7. Lift the hydraulic oil filter out of the filter housing.

NOTICE: Dispose of all fluids, filters, and containers in an environmentally safe manner and in accordance with local laws and regulations. Check with local environmental and recycling centers or your dealer for correct disposal information.

7-32

7 - MAINTENANCE

8. Insert the new hydraulic oil filter into the filter housing.

Observe the position of the locking cam.

RAIL15COM0183AA

7

RAIL15COM0184AA

8

RAIL15COM0185AA

9

9. Turn the hydraulic oil filter fully clockwise to the stop.

10. Lightly oil the O-ring on the filter cap.

11. Install the hydraulic oil tank cap.

12. Torque the hydraulic oil tank cap to: (14.75 lb ft).

20.00 N·m

Fill the hydraulic oil tank 13. Remove the cap on the hydraulic oil filler neck.

RAIL15COM0176AA

7-33

10

7 - MAINTENANCE

14. Fill with hydraulic oil.

RAIL15COM0140AA

11

RAIL15COM0176AA

12

15. Grease the O-ring of the hydraulic oil cap.

16. Install the cap on the hydraulic oil tank.

7-34

7 - MAINTENANCE

Every 500 hours of operation or every 6 months

Fuel filter WARNING Chemical hazard!

When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.

Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals.

Failure to comply could result in death or serious injury.

W0371A

Change the fuel filter every 500 hours or every six months.

1. Open the engine hood.

2. Close the fuel shutoff valve on the fuel filter water separator.

RAIL15COM0160AA

1

RAIL15COM0173AA

2

RAIL15COM0171AA

3

3. Clean the outside of the fuel filter.

4. Remove the fuel filter.

5. Clean the sealing face of the filter holder.

7-35

7 - MAINTENANCE

6. Replace the fuel filter with a new one.

7. Check the condition of the O-ring. Replace if necessary.

RAIL15COM0170AA

4

RAIL15COM0172AA

5

8. Manually tighten the new fuel filter by hand until the gasket seals. Then tighten the fuel filter by another half-turn.

7-36

7 - MAINTENANCE

Clean the fuel filter water separator Clean the fuel filter water separator every 500 hours or every six months.

1. Clean the outside of the water separator (2).

2. Close the fuel shut off valve (1) on the water separator.

Turn it to OFF. 3. Remove the filter housing (3).

4. Clean the water separator (2).

5. Install the filter housing (3).

6. Open the fuel shut off valve (1) on the water separator.

Turn it to ON.

RAIL15COM0175AA

NOTICE: Hand-tighten the fuel filter water separator.

7-37

1

7 - MAINTENANCE

Engine air filter - Replace Replace the inner air filter element every 500 hours or every six months.

1. Open the engine hood.

2. Pull the yellow tab to unlock the cover of the air filter housing.

RAIL15COM0228AA

1

RAIL15COM0229AA

2

RAIL15COM0224AA

3

3. Turn the cover counter-clockwise and remove the cover.

4. Remove the outer air filter element.

A. Replace the filter if you notice damage to the sides or edges. If you do not notice damage, continue to the next step.

B. Examine the inside of the filter. If the filter has dust and debris on the inside, replace the filter. If the filter is clean continue to the next step.

C. Lightly tap the ends of the filter against the palm of your hand. Never tap the ends against a hard surface.

D. Shine a light inside the filter. Replace the filter if you see light spots or deteriorated areas. If no damage is apparent, use the same filter.

NOTE: Clean the outer air filter element a maximum of six times and then replace.

7-38

7 - MAINTENANCE

5. Remove the inner air filter element.

6. Clean the inside of the air filter housing with a lint-free cloth.

RAIL15COM0226AA

4

RAIL15COM0227AA

5

RAIL15COM0224AA

6

RAIL15COM0228AA

7

7. Install the new inner air filter element. Do not clean.

8. Install the outer air filter element.

9. Install the cover of the air filter housing.

10. Turn the cover of the air filter housing clockwise.

11. Push the yellow tab to lock the cover of the air filter housing.

12. Close the engine hood.

7-39

7 - MAINTENANCE

Engine oil and filter WARNING Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in death or serious injury.

W0330B

Drain the engine oil and replace the engine oil filter after the first 50 hours and first 250 hours for a new machine.

After the initial 50-hour and 250-hour services, drain the engine oil and replace the engine oil filter every 500 hours or six months, or as required.

Type of oil Capacity

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

Drain the engine oil 1. Locate the engine oil drain on the left-hand side of the machine between the front chassis and rear chassis.

2. Turn the machine all the way to the right. This will provide easy access to the engine oil drain.

3. Place a suitable container under the engine oil drain.

RAIL15COM0187AA

1

RAIL15COM0188AA

2

4. Turn the engine oil drain plug counter-clockwise to drain the engine oil. Engine oil will immediately start to flow.

NOTE: Drain the engine oil when it is warm. Warm oil (not hot) will flow faster.

5. Turn the engine oil drain plug clockwise to close the engine oil drain. Torque the engine oil drain to: 54.2 – 63.7 N·m (40.0 – 47.0 lb ft).

NOTICE: Dispose of all fluids filters, and containers in an environmentally safe manner and in accordance with local laws and regulations. Check with local environmental and recycling centers or your dealer for correct disposal information.

7-40

7 - MAINTENANCE

Replace the engine oil filter 6. Open the engine hood.

7. Place a rag under the engine oil filter to collect oil once you remove the filter.

8. Remove the engine oil filter with a filter wrench or by hand.

9. Dispose of the filter and collected oil in accordance with local, regional, and federal regulations.

10. Use a clean cloth and wipe the sealing surface of the oil filter base to remove all dirt.

RAIL15COM0167AA

3

RAIL15COM0189AA

4

RAIL15COM0156AA

5

11. Apply a thin layer of engine oil to the gasket of the new oil filter.

12. Turn the new oil filter onto the base until the gasket makes contact with the base.

13. Torque the engine oil filter to: 19.0 – 23.0 N·m (14.0 – 17.0 lb ft) or use the filter wrench to turn the engine oil filter one additional turn.

NOTICE: Only use genuine, specified filters.

Fill the engine oil tank 14. Fill at either the filler neck (2) on the left-hand side of the engine or at the filler neck (1) on the engine.

NOTE: After you refill the engine oil, wait 5 min to allow the oil to drain to the sump before you check the oil level.

15. Close the engine hood.

7-41

7 - MAINTENANCE

Every 1000 hours or annually

Ventilation filter for the hydraulic oil tank WARNING Chemical hazard!

When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions.

Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals.

Failure to comply could result in death or serious injury.

W0371A

Replace the ventilation filter for the hydraulic oil tank after the first 500 hours of operation for a new machine. Then replace the ventilation filter at every 1000 hours of operation or annually.

The hydraulic oil fill cap is also a ventilation filter for the hydraulic oil tank.

1. Open the engine hood.

2. Remove the ventilation filter.

3. Replace the ventilation filter with a new filter.

4. Grease the O-ring of the new ventilation filter.

5. Close the engine hood.

RAIL15COM0176AA

7-42

1

7 - MAINTENANCE

Hydraulic oil and filter WARNING Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in death or serious injury.

W0330B

WARNING Pressurized system!

Never attempt to drain fluids or remove filters when the engine is running. Turn off the engine and relieve all pressure from pressurized systems before servicing the machine.

Failure to comply could result in death or serious injury.

W0905A

Drain the hydraulic oil and replace the hydraulic oil filter after the first 500 hours of operation for a new machine.

After the first 500 hours of operation, drain the hydraulic oil and replace the hydraulic oil filter at every 1000 hours of operation or annually, or as required.

Type of hydraulic oil Capacity

Service specifications CASE AKCELA NEXPLORE™ FLUID 37.0 L (9.77 US gal)

NOTICE: Always consult with your authorized dealer before you switch from mineral oil to synthetic oil or mix oils from different brands.

Drain the hydraulic oil 1. Place a suitable container (minimum 30.0 L (7.9 US gal) capacity) under the hydraulic oil drain.

RAIL15COM0178AA

1

RAIL15COM0179AA

2

2. Remove the hydraulic oil tank cap.

7-43

7 - MAINTENANCE

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

NOTE: Drain the hydraulic oil when the oil is still warm, but not hot. The oil will flow more easily.

4. Secure the screw connections with LOCTITE® 242® Hand-tighten the screw connections. Do not torque the screw connections. See 7-1.

RAIL15COM0178AA

3

NOTE: Replace the hydraulic oil filter whenever you drain the hydraulic oil. Replace the hydraulic oil filter before you fill the hydraulic tank with new oil.

Replace the hydraulic oil filter 5. Remove the hydraulic oil tank cap.

RAIL15COM0180AA

4

RAIL15COM0181AA

5

RAIL15COM0182AA

6

6. Unlock the hydraulic oil filter element.

7. Lift the hydraulic oil filter out of the filter housing.

NOTICE: Dispose of all fluids, filters, and containers in an environmentally safe manner and in accordance with local laws and regulations. Check with local environmental and recycling centers or your dealer for correct disposal information.

7-44

7 - MAINTENANCE

8. Insert the new hydraulic oil filter into the filter housing.

Observe the position of the locking cam.

RAIL15COM0183AA

7

RAIL15COM0184AA

8

RAIL15COM0185AA

9

9. Turn the hydraulic oil filter fully clockwise to the stop.

10. Lightly oil the O-ring on the filter cap.

11. Install the hydraulic oil tank cap.

12. Torque the hydraulic oil tank cap to: (14.75 lb ft).

20.00 N·m

Fill the hydraulic oil tank 13. Remove the cap on the hydraulic oil filler neck.

RAIL15COM0176AA

7-45

10

7 - MAINTENANCE

14. Fill with hydraulic oil.

RAIL15COM0140AA

11

RAIL15COM0176AA

12

15. Grease the O-ring of the hydraulic oil cap.

16. Install the cap on the hydraulic oil tank.

7-46

7 - MAINTENANCE

Fuel tank sediment Drain water and sediment from the fuel tank every 1000 hours or every year or as required.

1. Place a suitable container under the fuel drain.

2. Remove the screw plug of the fuel drain with a square socket wrench.

3. Drain the water and sediment. Allow approximately 0.50 L (0.13 US gal) of fluid to drain.

4. Install the screw plug. Secure the screw plug with LOCTITE® 242®.

RAIL15COM0192AA

1

NOTICE: Dispose of all fluids, filters, and containers in an environmentally safe manner and in accordance with local laws and regulations. Check with local environmental and recycling centers or your dealer for correct disposal information.

7-47

7 - MAINTENANCE

Articulated joint pivot Maintain the articulated joint pivot every 1000 hours or every year, or as required.

If the articulated joint pivot makes a grinding noise as you operate the machine, contact your authorized dealer.

RAIL15COM0199AA

7-48

1

7 - MAINTENANCE

Pendulum joint Maintain the pendulum joint every 1000 hours or every year, or as required.

If the pendulum joint makes a grinding noise as you operate the machine, contact your authorized dealer.

SVIL13COM0193AB

7-49

1

7 - MAINTENANCE

As required

Fuel tank Drain the fuel from the fuel tank as required.

1. Place a suitable container under the fuel drain.

2. Remove the screw plug of the fuel drain with a square socket wrench.

3. Drain the diesel fuel.

4. Install the screw plug. Secure the screw plug with LOCTITE® 242®.Do not torque. See 7-1.

RAIL15COM0192AA

1

NOTICE: Dispose of all fluids, filters, and containers in an environmentally safe manner and in accordance with local laws and regulations. Check with local environmental and recycling centers or your dealer for correct disposal information.

7-50

7 - MAINTENANCE

Hydraulic oil and filter WARNING Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in death or serious injury.

W0330B

WARNING Pressurized system!

Never attempt to drain fluids or remove filters when the engine is running. Turn off the engine and relieve all pressure from pressurized systems before servicing the machine.

Failure to comply could result in death or serious injury.

W0905A

Drain the hydraulic oil and replace the hydraulic oil filter after the first 500 hours of operation for a new machine.

After the first 500 hours of operation, drain the hydraulic oil and replace the hydraulic oil filter at every 1000 hours of operation or annually, or as required.

Type of hydraulic oil Capacity

Service specifications CASE AKCELA NEXPLORE™ FLUID 37.0 L (9.77 US gal)

NOTICE: Always consult with your authorized dealer before you switch from mineral oil to synthetic oil or mix oils from different brands.

Drain the hydraulic oil 1. Place a suitable container (minimum 30.0 L (7.9 US gal) capacity) under the hydraulic oil drain.

RAIL15COM0178AA

1

RAIL15COM0179AA

2

2. Remove the hydraulic oil tank cap.

7-51

7 - MAINTENANCE

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

NOTE: Drain the hydraulic oil when the oil is still warm, but not hot. The oil will flow more easily.

4. Secure the screw connections with LOCTITE® 242® Hand-tighten the screw connections. Do not torque the screw connections. See 7-1.

RAIL15COM0178AA

3

NOTE: Replace the hydraulic oil filter whenever you drain the hydraulic oil. Replace the hydraulic oil filter before you fill the hydraulic tank with new oil.

Replace the hydraulic oil filter 5. Remove the hydraulic oil tank cap.

RAIL15COM0180AA

4

RAIL15COM0181AA

5

RAIL15COM0182AA

6

6. Unlock the hydraulic oil filter element.

7. Lift the hydraulic oil filter out of the filter housing.

NOTICE: Dispose of all fluids, filters, and containers in an environmentally safe manner and in accordance with local laws and regulations. Check with local environmental and recycling centers or your dealer for correct disposal information.

7-52

7 - MAINTENANCE

8. Insert the new hydraulic oil filter into the filter housing.

Observe the position of the locking cam.

RAIL15COM0183AA

7

RAIL15COM0184AA

8

RAIL15COM0185AA

9

9. Turn the hydraulic oil filter fully clockwise to the stop.

10. Lightly oil the O-ring on the filter cap.

11. Install the hydraulic oil tank cap.

12. Torque the hydraulic oil tank cap to: (14.75 lb ft).

20.00 N·m

Fill the hydraulic oil tank 13. Remove the cap on the hydraulic oil filler neck.

RAIL15COM0176AA

7-53

10

7 - MAINTENANCE

14. Fill with hydraulic oil.

RAIL15COM0140AA

11

RAIL15COM0176AA

12

15. Grease the O-ring of the hydraulic oil cap.

16. Install the cap on the hydraulic oil tank.

7-54

7 - MAINTENANCE

Hydraulic oil cooler Clean the hydraulic oil cooler at a location that has a cleaner collection system to prevent soil and water resource contamination.

A dirty hydraulic oil cooler will cause a reduction in cooling performance and an increase in temperature of the engine coolant and the hydraulic oil.

1. Check the cooling ribs of the hydraulic oil cooler for dirt and clogs.

2. Clean the cooling ribs of the hydraulic oil cooler with compressed air or with water (steam).

RAIL15COM0198AA

NOTICE: Never clean the hydraulic oil cooler with high pressure water.

7-55

1

7 - MAINTENANCE

Radiator Clean the radiator at a location that has a cleaner collection system to prevent soil and water resource contamination.

Clean the radiator as required.

1. Check the cooling ribs of the radiator for dirt and clogs.

2. Clean the cooling ribs of the radiator with compressed air or with water (steam).

RAIL15COM0196AA

NOTICE: Never clean the radiator with high pressure water.

7-56

1

7 - MAINTENANCE

Cleaning the machine When the work is complete, clean the machine to remove major impurities.

Perform an overall cleaning on a weekly basis.

Clean the machine daily if you work on cohesive soils, concrete or lime stabilizations.

To clean the machine follow the procedures below: 1.

Stop the engine and remove the ignition key.

2.

Disconnect the battery master switch.

3.

Before pressure cleaning with water or steam, plug all of the ports with protective caps.

4.

Never use aggressive or easily ignitable cleaners.

5.

Do not expose electric parts or insulation material to direct water or streams of steam.

6.

To avoid soil or water resource contamination, clean the machine at a location that has proper equipment to collect and dispose of the cleaning agents.

7.

After you clean the machine, remove the protective caps.

8.

Connect the battery master switch.

7-57

7 - MAINTENANCE

Battery WARNING Battery acid causes burns. Batteries contain sulfuric acid.

Avoid contact with skin, eyes or clothing. Antidote (external): Flush with water. Antidote (eyes): flush with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large quantities of water or milk. Do not induce vomiting. Seek medical attention immediately.

Failure to comply could result in death or serious injury.

W0111A

WARNING Explosion hazard!

Sparks from the contact area may ignite gases escaping from the discharged battery. Because of this risk, always connect the negative terminal to the ground as far away from the discharged batteries as possible. Wash hands after handling battery components.

Failure to comply could result in death or serious injury.

W1092A

WARNING Chemical hazard!

Battery acid can cause severe burns. Some batteries have a ventilation tube. If there is battery acid in the tube, this acid can be released when the battery is turned upside down. If you turn the battery upside down, point the ventilation tube away from you and any other people in the area.

Failure to comply could result in death or serious injury.

W1084A

WARNING Battery gas can explode!

To prevent an explosion: 1. Always disconnect the negative (-) battery cable first. 2. Always connect the negative (-) battery cable last. 3. Do not short circuit the battery posts with metal objects. 4. Do not weld, grind, or smoke near a battery.

Failure to comply could result in death or serious injury.

W0011A

1. Turn the battery master switch to the OFF position.

RAIL15COM0116AA

7-58

1

7 - MAINTENANCE

2. Disconnect the negative (-) terminal.

RAIL15COM0200AA

2

RAIL15COM0201AA

3

RAIL15COM0204AA

4

RAIL15COM0202AA

5

3. Disconnect the positive (+) terminal.

4. Remove the mounting bracket.

5. Lift the battery out of the engine compartment.

6. Set the new battery in place.

7. Connect the battery. Connect the positive (+) terminal first, then connect the negative (-) terminal.

7-59

7 - MAINTENANCE

8. Turn the battery master switch to the ON position.

RAIL15COM0118AA

7-60

6

7 - MAINTENANCE

Articulated joint pivot Maintain the articulated joint pivot every 1000 hours or every year, or as required.

If the articulated joint pivot makes a grinding noise as you operate the machine, contact your authorized dealer.

RAIL15COM0199AA

7-61

1

7 - MAINTENANCE

Pendulum joint Maintain the pendulum joint every 1000 hours or every year, or as required.

If the pendulum joint makes a grinding noise as you operate the machine, contact your authorized dealer.

SVIL13COM0193AB

7-62

1

7 - MAINTENANCE

Front work lights and parking lights (optional) Replace the bulbs of the front work lights and the front parking lights as required.

1. Open the engine hood to access the work lights (1) and the parking lights (2).

RAIL15COM0203AA

Work light (1) 1. Remove the plug from the work light.

2. Remove the rubber guard.

3. Press on the end of the securing clip and remove it.

4. Remove and replace the bulb with a new bulb of the same type and power.

5. Install the securing clip.

6. Install the rubber guard.

NOTICE: To prevent water from entering the work light, make sure the rubber guard sits firmly on the glass body of the work light unit.

7. Plug in the work light.

Parking light (2) 1. Remove the bulb from the lamp holder.

2. Replace the bulb with a new bulb of the same type and power.

7-63

1

7 - MAINTENANCE

Turn signal and flasher bulb (Optional) Replace the bulb of the turn signals/flashers as required.

1. Remove the screw from the center of the turn signal/ flasher light housing.

2. Replace the defective bulb with a new one of the same type and wattage.

3. Install the screw that holds the turn signal/flasher light housing in place.

NOTE: Do not touch the glass of the new bulb with your fingers. Sweat on your hands can burn into the glass and reduce bulb lifetime.

RAIL15COM0207AA

7-64

1

7 - MAINTENANCE

Rear work light and tail lights (optional) Replace the bulbs of the rear work light and the tail lights as required.

Rear work light 1. Remove the two screws that hold the work light in place.

2. Remove the entire work light.

3. Remove the plug from the rear of the lamp unit.

4. Remove the rubber guard.

5. Press on the end of the securing clip and remove it.

6. Replace the defective bulb with a new one of the same type and wattage.

7. Install the securing clip.

8. Install the rubber guard.

RAIL15COM0205AA

1

RAIL15COM0205AA

2

NOTICE: To prevent water from entering the work light, make sure the rubber guard sits firmly on the glass body of the work light unit.

9. Plug in the work light.

10. Install the two screws that hold the work light in place.

Tail lights 11. Remove the screw from the center of the tail light housing.

12. Remove the tail light housing.

13. Replace the defective bulb with a new one of the same type and power.

14. Install the screw that secures the tail light housing to the machine.

7-65

7 - MAINTENANCE

Rotating beacon light (optional) Replace the bulb of the rotating beacon light as required.

1. Remove the theft-protection screw.

RAIL15COM0206AA

1

RAIL15COM0208AA

2

RAIL15COM0209AA

3

RAIL15COM0208AA

4

2. Lift the cover off with a clockwise twisting motion.

3. Press the two lugs of the bulb holder together.

4. Remove the bulb from the connector.

5. Replace the defective bulb with a new one of the same type and wattage.

NOTE: Do not touch the glass of the new bulb with your fingers. Sweat on your hands can burn into the glass and reduce bulb lifetime.

6. Install the cover.

7-66

7 - MAINTENANCE

7. Install the theft-protection screw.

RAIL15COM0206AA

7-67

5

7 - MAINTENANCE

Water tank and sprinkler - Drain Before winter, drain the water tank and drain the water from the sprinkling system.

Drain the water tank as required.

Drain the water tank 1. Use the machine’s ignition key to unlock the cap to the water tank. Remove the cap of the water tank.

RAIL15COM0212AA

1

RAIL15COM0195AA

2

RAIL15COM0210AA

3

2. Remove the drain plug with a wrench and drain the tank.

3. Install the drain plug.

Drain the sprinkler 4. Press the black plastic ring of the sprinkler quick-release coupling against the screw connection.

5. Pull the sprinkler hose off of the quick-release coupling.

6. Drain the water.

7. Turn the sprinkler on and let the pump run briefly.

8. Clean the sprinkler pipes with nozzles. See page 7-70.

9. Connect the sprinkler hose.

10. Clean the water tank and the filter strainer.

7-68

7 - MAINTENANCE

11.

WARNING Electrical shock hazard!

Before working on any part of the electrical system, disconnect the battery ground cable.

Complete all electrical work before connecting the cable.

Failure to comply could result in death or serious injury.

W0129A

Remove and clean the plastic container of the water filter.

NOTICE: You must remove the plastic container if there is a risk of freezing temperatures. The water will crack the container if it were to freeze.

RAIL15COM0211AA

4

RAIL15COM0212AA

5

12. Install and lock the cap of the water tank.

7-69

7 - MAINTENANCE

Water tank - Fill Fill the water tank as required.

1. Use the machine’s ignition key to unlock the cap to the water tank.

2. Remove the cap to the water tank.

3. Fill the water tank with clean water.

4. Install and lock the cap of the water tank.

RAIL15COM0212AA

1

RAIL17COM0002AA

1

Sprinkler nozzles Clean the sprinkler nozzles as required.

1. Remove the sprinkler nozzles that have a blockage.

2. Use compressed air to clean the sprinkler nozzles.

3. Install the sprinkler nozzles.

Pneumatic wheel scrapers (DV45CC) 1. Check the scrapers for proper clearance of 3 – 5 mm (0.118 – 0.197 in). Adjust as necessary.

7-70

7 - MAINTENANCE

Fuse and relay locations

Fuses WARNING Electrical shock hazard!

Before you work on any part of the electrical system, disconnect the battery ground cable or turn the battery disconnect switch off (if equipped).

Complete all electrical work before you reconnect the cable.

Failure to comply could result in death or serious injury.

W1393A

Engine compartment fuses Locate the fuses in the engine compartment.

Always replace a defective fuse with a functioning fuse of the same amperage (based on the label or color of the fuse). The fuse numbers are on the fuse box.

Fuses F21 F22 F23 F24

Power 40 A 15 A 15 A 10 A

Fuses-protect circuit Pull-in solenoid Diesel pump, alternator Reserve Reserve RAIL15COM0300AA

1

RAIL15COM0214AA

2

Steering column fuses Fuses F1 F2

Power 10 A 7.5 A

F3

7.5 A

F4 F5 F6 F7

10 A 15 A 7.5 A 10 A

F8 F9 F10

10 A 3A 10 A

F11 F12 F13 F14

15 A 10 A 10 A 1A

F15 F16

25 A 15 A

Fuses-protect circuit Hazard warning light 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 Controller Controller, drive pump, brake valve, holding solenoid Sprinkling Reserve Vibration Brake pressure switch, asphalt temperature sensor Hydraulic oil cooler Reserve

1. Remove the four fastening screws from the fuse box.

2. Remove the cover 3. Replace the defective fuse.

NOTICE: Always replace the defective fuse with a fuse of the same amperage.

7-71

7 - MAINTENANCE

Storage

Short-term preservation and storage for 1-2 month Short-term storage Store the machine as follows: 1.

Wash and clean the machine.

2.

Run the engine until it is at operating temperature before you store the machine.

3.

Park the machine on a firm, level surface at a safe place (with no risk of natural disaster - floods, landslides, fire, etc., to the machine).

4.

Repair any paint damage.

5.

Grease all grease points, control cables, joints of the controls, etc.

6.

Drain the water tank. See 7-68.

7.

Check for the correct antifreeze properties of the coolant.

8.

Check the battery charge and recharge if necessary.

9.

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

10. Protect the machine against corrosion. Spray the preservation agent (applied spraying), in places which are prone to corrosion.

11. Move the travel control lever to the neutral position.

12. Secure the machine form unauthorized start-up and unintentional machine movement.

13. Disconnect the battery master switch. See 3-21 14. Remove the ignition key.

If you preserve the machine as explained above, no action is necessary when you return the machine to service.

NOTICE: Do not start the engine while the machine is in storage..

7-72

7 - MAINTENANCE

Machine preservation and storage for more than two months For long term storage (more than 2 months), follow the procedures on page 7-72. as well as the additional steps below: 1.

Drain the diesel fuel. See page 7-50.

2.

Remove the battery. See page 7-58.

3.

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

4.

Apply a special preservation agent to protect rubber parts.

5.

On DV45CC unit, raise and block the tires off the ground to avoid flat spots on the tires.

6.

Cover the engine intake and exhaust ports with double polyethylene foil. Secure this foil with adhesive tape.

7.

Preserve the engine per the engine manufacturer’s instruction manual The engine manufacturer’s instruction manual is located in the manual storage compartment under the hood. Visibly mark that the engine is preserved.

NOTICE: Inspect the condition of preservation after 6 months and renew the preservation conditions as necessary.

Before you return the machine to service, wash the machine with high-pressure hot water steam to remove the preservation agents. If necessary, use de-greasers.

Storage in freezing conditions The following should be performed whenever the unit is stored in freezing conditions. When you follow this procedure you will minimize the risk with frozen and broken components.

1. Drain the water tank and sprinkler bar as described in 7-68.

2. Start the water pump for 20 seconds which will purge the water pipes.

3. Remove the sprinkling bar from the machine and drain out the water from bar and nozzles.

4. Remove the plastic container on the water filter from unit.

5. Drain the emulsion tank ( DV45CC only).

7-73

7 - MAINTENANCE

7-74

8 - TROUBLESHOOTING

8 - TROUBLESHOOTING###_8_### Fault code resolution

Error codes When the controller recognizes an error, the error code will display on the screen.

RAIL15COM0102AA

1

Display upon start-up Display -11 -12 -13 -14 -15

Error

Remedy

Seat contact open Travel control lever is deflected 2 Travel control levers (option) Both travel control levers are deflected Parking brake is activated Diesel engine is not running

Sit down Move the travel control into the neutral position Move the travel control levers into the neutral position Release the parking brake Start the engine

NOTE: The display remains blank when the machine is in operation unless your machine is equipped with the optional infrared temperature sensor. In this case, the surface temperature will display.

If errors are recognized, the error warning lamp illuminates and the error code will display on the screen. If more than one error is present, the error codes will display at in 5 s intervals.

Display during operation Display F21

Error Travel control lever right

F25

Effect Vehicle standstill. Limited driving is possible with the left travel control lever, if installed Move travel control lever, neutral Vehicle standstill. Limited driving switch to the right is possible with the left travel control lever, if installed Vehicle standstill. Limited driving Travel control lever left is possible with the right travel control lever.

Move travel control lever, neutral Vehicle standstill. Limited driving switch to the left is possible with the right travel control lever.

Sprinkler potentiometer Sprinkler function is switched off

F26

Oil temperature sensor

F27

PWM pump forwards

F28

PWM pump backwards

F22

F23

F24

Temperature control is switched off Vehicle standstill. Driving in a forward direction is possible Vehicle standstill. Driving in a backward direction is possible

8-1

Remedy Check sensor, wiring harness, and connector of the drive control.

Check sensor, wiring harness, and connector of the drive control.

Check sensor, wiring harness, and connector of the drive control.

Check sensor, wiring harness, and connector of the drive control.

Check sensor, wiring harness, and connector of the drive control.

Check sensor, wiring harness, and connector of the drive control.

Check magnet, wiring harness, and connector of the drive control.

Check magnet, wiring harness, and connector of the drive control.

8 - TROUBLESHOOTING

Display F29

Error Vibration relay

Effect Vibration is no longer actuated

F30

Brake valve

Vehicle standstill

F31

Low voltage

Vehicle standstill

F32

Oil temperature too high

F33 F34 F35

F36

F37

F38

F39

F40 F41 F42

F43

Remedy Check magnet, wiring harness, and connector of the drive control.

Check magnet, wiring harness, and connector of the drive control.

Check magnet, wiring harness, and connector of the drive control.

Wait until the temperature drops.

Driving in emergency, driving mode is possible if the pump has no longer been actuated.

Power supply, 8 V No reaction Check the supply voltage, replace the controller unit.

Power supply, 2.5 V Vehicle standstill. Controller Check the supply voltage, replace central switch is opened. the controller unit.

Ability of the pump to be switched Vehicle standstill. Except for the Check the drive pump magnets, off display message, no outputs are wiring harness, and connector of the drive control. Replace the actuated. controller.

Vehicle standstill PWM pump flow, forwards Check the drive pump magnets, wiring harness, and connector of the drive control. Replace the controller.

Vehicle standstill PWM pump flow, backwards Check the drive pump magnets, wiring harness, and connector of the drive control. Replace the controller.

Vehicle standstill Wrong direction of travel Replace the controller. Check the wiring harness and connector of the drive control.

Current when the control lever is Vehicle standstill Replace the controller. Check the in neutral wiring harness and connector of the drive control.

Program sequence Vehicle standstill Replace the controller Starting condition Except for the display message, Check the supply voltage no outputs are actuated.

No temperature display Infrared temperature sensor Check the infrared sensor, wiring harness, and connector of the drive control unit.

Diesel engine speed Load limit controller (under the Check for the correct throttle seat) does not become active position. Check for full movement of the throttle. Check that the engine RPM is between 1450 – 2050 RPM. Check for loose throttle cable mounting or cable movement that is not enough to reach the desired RPM. Readjust the throttle cable to control the diesel engine speed.

8-2

8 - TROUBLESHOOTING

Bus error messages Display Bus

Effect No connection is present between the controller unit and the display unit. The following functions are not available: • Oil temperature warning lamp • Brake pressure lamp • Error warning lamp • Seat contact warning buzzer • Reversing alarm • Sprinkler The travel control lever sprinkler button is still available.

• Fault display

8-3

Remedy Check the wiring harness, display unit, and the controller unit.

8 - TROUBLESHOOTING

8-4

9 - SPECIFICATIONS

9 - SPECIFICATIONS###_9_### General specifications DV36 Service weight of CECE Maximum service weight Static linear load Inside turning radius Amplitude Maximum compaction force per roller drum Gradient with and/or without vibration.

Engine Performance — ISO 3046 Operating speed Travel speed Steering angle / pivoting Vibration frequency 2100 RPM / 2400 RPM

DV36 Specifications 3725 kg (8212 lb) 4300 kg (9480 lb) 457.45 N/mm (80.10 lbf/in) 2581 mm (101.61 in) 0.360 mm (0.014 in) / 0.550 mm (0.022 in) 50 kN 30% / 40% YANMAR $TNV88 — EPA Tier 4 interim 30.0 kW (40.8 Hp) 2400 RPM 0.0 – 10.0 km/h (0.0 – 6.2 mph) +/- 32° / +/- 8° 45 Hz / 57 Hz

DV45 Service weight of CECE Maximum service weight Static linear load Inside turning radius Amplitude Maximum compaction force per roller drum Gradient with and/or without vibration.

Engine Performance — ISO 3046 Operating speed Travel speed Steering angle / pivoting Vibration frequency 2100 RPM / 2400 RPM

DV45 Specifications 4650 kg (10251 lb) 5100 kg (11244 lb) 537.4 N/mm (94.1 lbf/in) 2621 mm (103.19 in) 0.360 mm (0.014 in) / 0.550 mm (0.022 in) 55 kN 30% / 40% YANMAR 4TNV88— EPA Tier 4 interim 30.0 kW (40.8 Hp) 2400 RPM 0.0 – 10.0 km/h (0.0 – 6.2 mph) +/- 32° / +/- 8° 45 Hz / 57 Hz

DV45CC Service weight of CECE Maximum service weight Static linear load Wheel load Inside turning radius Amplitude Gradient with and/or without vibration.

Engine Performance — ISO 3046 Operating speed Travel speed Steering angle / pivoting Vibration frequency 2100 RPM / 2400 RPM

DV45CC Specifications 4325 kg (9535 lb) 5100 kg (11244 lb) 537.4 N/mm (94.1 lbf/in) 541 kg (1193 lb) 2621 mm (103.19 in) 0.360 mm (0.014 in) / 0.550 mm (0.022 in) 30% / 40% YANMAR 4TNV88— EPA Tier 4 interim 30.0 kW (40.8 Hp) 2400 RPM 0.0 – 10.0 km/h (0.0 – 6.2 mph) +/- 32° / +/- 8° 45 Hz / 57 Hz

9-1

9 - SPECIFICATIONS

Consumables and 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)

9-2

9 - SPECIFICATIONS

Dimensions Dimensional diagram – DV36, DV45

RAIL15COM0216GA

DV36 DV45 DV45CC

A 1950 mm (76.77 in) 1950 mm (76.77 in) 2018 mm (79.45 in)

B 1423 mm (56.02 in) 1503 mm (59.17 in) 1463 mm (57.60 in)

9-3

1

W 1300 mm (51.18 in) 1380 mm (54.33 in) 1380 mm (54.33 in)

W1 1341 mm (52.80 in) 1421 mm (55.94 in) 1421 mm (55.94 in)

9 - SPECIFICATIONS

RAIL15COM0405GA

9-4

2

Index ###_Index_###

Air filter service indicator . . . .

Air filter vacuum valve . . . . .

Air intake - Check . . . . . . .

Articulated joint lock . . . . . .

Articulated joint pivot . . . . .

Assisted starting (Jump-starting)

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

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

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . 7-19 . . 7-25 . . 7-18 . . 5-1 7-48, 7-61 . . . 4-6

Backup alarm . . . . . . .

Battery . . . . . . . . . .

Battery charge - Check . . .

Battery master switch . . . .

Before starting the engine . .

Biodiesel fuel - Biodiesel fuels Brakes . . . . . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

B . . . . . . . . . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

C California proposition 65 warning — California Proposition 65 Warning Cleaning the machine . . . . . . . . . . . . . . . . . . . . . .

Clean the fuel filter water separator . . . . . . . . . . . . . . . .

Consumables and capacities . . . . . . . . . . . . . . . . . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . 2-9 . . . 7-57 . . . 7-37 . 7-8, 9-2

. . . . . . .

. . . .

. . . . . . .

. . . . . . .

3-19 7-58 7-19 3-21 4-2 7-5 7-24

D Diesel fuel - Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Display screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Ecology and the environment. . . . . . . .

Electro-Magnetic Compatibility (EMC) . . . .

Emission control system Warranty – USA only Emulsion level (DV45CC) . . . . . . . . .

Emulsion sprinkling (DV45CC) . . . . . . .

Engine air filter - Replace . . . . . . . . .

Engine coolant level - Check . . . . . . . .

Engine oil and filter . . . . . . . . . . . .

Engine oil and filter (Initial) . . . . . . . . .

Engine oil level - Check . . . . . . . . . .

Error codes . . . . . . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

E . . . . . . . . . . . . . . . . . . . . . .

Front controls . . . . . . . . . . . . . .

Front work lights and parking lights (optional) .

Fuel filter . . . . . . . . . . . . . . . .

Fuel filter water separator - Check . . . . .

Fuel level - Check . . . . . . . . . . . .

Fuel tank . . . . . . . . . . . . . . . .

Fuel tank sediment . . . . . . . . . . . .

Fuses . . . . . . . . . . . . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . .

. . 2-10 . . 1-5 . . 1-15 . . 7-21 . . 6-4 . . 7-38 . . 7-15 . . 7-40 7-22, 7-27 . . . 7-12 . . . 8-1

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

. . . . . . . .

F . . . . . . . .

. . . . . . . .

. . . . . . . .

3-10 7-63 7-35 7-18 7-11 7-50 7-47 7-71

G General maintenance information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1 9-1

H Hand signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-11

Heated seat (option) . .

Hydraulic oil and filter . .

Hydraulic oil cooler . . .

Hydraulic oil level - Check

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . . . 3-16 7-31, 7-43, 7-51 . . . . . 7-55 . . . . . 7-13

I Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2

L Left-hand side controls (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Lifting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 M Machine components . . . . . . . . . . . . . . . . . .

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

Machine preservation and storage for more than two months .

Machine travel . . . . . . . . . . . . . . . . . . . . .

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

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. 1-10 . 1-9 . 7-73 . 4-9 . 7-9

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

1-1

O Opening the hood. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Operator's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-4 1-8 3-2

P . . . . . . . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . .

R Radiator . . . . . . . . . . . . . . . . . . . . . . .

Rear work light and tail lights (optional) . . . . . . . . .

Recommended engine oil for operating temperature ranges Right-hand side controls . . . . . . . . . . . . . . . .

Roller drum scrapers (option). . . . . . . . . . . . . .

Roller drum scrapers - Check . . . . . . . . . . . . .

Roll Over Protective Structure (ROPS) Fold up/down . . .

Rotating beacon (option). . . . . . . . . . . . . . . .

Rotating beacon light (optional) . . . . . . . . . . . . .

Run-in period of a new machine . . . . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

7-56 7-65 7-3 3-13 3-20 7-17 5-4 3-17 7-66 4-1

S . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

2-2 2-1 2-14 7-26 7-72 7-70 7-16 6-3 4-3 7-27 4-7 7-73 3-4

Pendulum joint . . . . . . . . . .

Pneumatic wheel scrapers (DV45CC) Pre-heating the system . . . . . .

Product identification . . . . . . .

Proper entry and exit . . . . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

Safety rules . . . . . . . . . . . . . . . . .

Safety rules and signal word definitions . . . . .

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

Seat switch and emergency stop . . . . . . . .

Short-term preservation and storage for 1-2 month Sprinkler nozzles . . . . . . . . . . . . . . .

Sprinkler system - Check . . . . . . . . . . .

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

Starting the engine . . . . . . . . . . . . . .

Steering cylinder . . . . . . . . . . . . . . .

Stopping the engine . . . . . . . . . . . . . .

Storage in freezing conditions . . . . . . . . .

Switches and control lamps . . . . . . . . . .

. . . . .

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

. . . . .

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

7-49, 7-62 . . 7-70 . . 4-5 . . 1-6 . . 3-1

T Tire pressure (DV45CC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21 Torque charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Towing the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Transport on a trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Turn signal and flasher bulb (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-64 V Vandalism protection cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Ventilation filter for the hydraulic oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30, 7-42 Vibration operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Water level gauge . . . . . .

Water level indicator . . . . .

Water tank and sprinkler - Drain Water tank - Fill. . . . . . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

W . . . . . . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

. . . .

3-18 7-20 7-68 7-70

Y Your compactor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4

Dealer’s stamp

CNH Industrial America LLC reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold.

Specifications, descriptions, and illustrative material herein are as accurate as known at time of publication, but are subject to change without notice.

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

© 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.

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.