Case PT240 Tier 3 Pneumatic Line Roller Service Manual PN 47703681 - PDF DOWNLOAD

PT240 Tier 3 Pneumatic Line Roller

SERVICE MANUAL

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

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

Part number 47703681 2nd edition English September 2015 Replaces part number 84287260A

SERVICE MANUAL PT240

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Contents INTRODUCTION Engine....................................................................................... 10 [10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

Transmission.............................................................................. 21 [21.118] Transmission/Rear drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1

Front axle system ....................................................................... 25 [25.400] Non-powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1

Rear axle system........................................................................ 27 [27.100] Powered rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1 [27.124] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2

Brakes and controls .................................................................... 33 [33.300] Pneumatic service brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1 [33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2

Hydraulic systems....................................................................... 35 [35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2

Pneumatic system ...................................................................... 36 [36.100] Pneumatic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.1

Frames and ballasting ................................................................. 39 [39.500] Vibratory roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1

Steering..................................................................................... 41 [41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1 [41.106] Tie rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2

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[41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3 [41.206] Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.4 [41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.5

Wheels ...................................................................................... 44 [44.511] Front wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1 [44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2

Cab climate control ..................................................................... 50 [50.104] Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1 [50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2

Electrical systems ....................................................................... 55 [55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.525] Cab engine controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.011] Fuel tank system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 [55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8 [55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9 [55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10 [55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11

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

Platform, cab, bodywork, and decals ............................................. 90 [90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 [90.114] Operator protections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2 [90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3

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INTRODUCTION

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Contents INTRODUCTION Foreword - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety rules - Personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety rules - Ecology and the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Safety rules - Shop and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Safety rules – Hydraulic contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Torque - Standard torque data for hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Basic instructions - Shop and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Product identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Part identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Product identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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INTRODUCTION

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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Safety rules - Personal safety Carefully study these precautions, and those included in the external attachment operators manual, and insist that they be followed by those working with and for you.

1.

Thoroughly read and understand this manual and the attachment Operator’s Manual before operating this or any other equipment.

2.

Be sure all people and pets are clear of the machine before starting. Sound the horn, if equipped, three times before starting engine.

3.

Only the operator should be on the machine when in operation. Never allow anyone to climb on to the machine while it is in motion. If the machine is equipped with an Instructors Seat, this must only be used for training purposes. Passengers must not be allowed to use the Instructors Seat.

4.

Keep all shields in place. Never work around the machine or any of the attachments while wearing loose clothing that might catch on moving parts.

5.

Observe the following precautions whenever lubricating the machine or making adjustments.

• Disengage all clutching levers or switches.

• Lower the attachment, if equipped, to the ground or raise the attachment completely and engage the cylinder safety locks. Completing these actions will prevent the attachment from lowering unexpectedly.

• Engage the parking brake.

• Shut off the engine and remove the key.

• Wait for all machine movement to stop before leaving the operators platform.

6.

Always keep the machine in gear while travelling downhill.

7.

The machine should always be equipped with sufficient front or rear axle weight for safe operation.

8.

Under some field conditions, more weight may be required at the front or rear axle for adequate stability. This is especially important when operating in hilly conditions or/when using heavy attachments.

9.

Always lower the attachment, shut off the engine, set the parking brake, engage the transmission gears, remove the key and wait for all machine movement to stop before leaving the operators platform.

10. If the attachment or machine should become obstructed or plugged; set the parking brake, shut off the engine and remove the key, engage the transmission gears, wait for all machine or attachment motion to come to a stop, before leaving the operators platform to removing the obstruction or plug.

11. Never disconnect or make any adjustments to the hydraulic system unless the machine and/or the attachment is lowered to the ground or the safety lock(s) is in the engaged position.

12. Use of the flashing lights is highly recommended when operating on a public road.

13. When transporting on a road or highway, use accessory lights and devices for adequate warning to the operators of other vehicles. In this regard, check local government regulations. Various safety lights and devices are available from your CASE CONSTRUCTION dealer.

14. Practice safety 365 days a year.

15. Keep all your equipment in safe operating condition.

16. Keep all guards and safety devices in place.

17. Always set the parking brake, shut off the engine and remove the key, engage the transmission gears, wait for all machine or attachment motion to come to a stop, before leaving the operators platform to service the machine and attachment.

18. Remember: A careful operator is the best insurance against an accident.

19. Extreme care should be taken in keeping hands and clothing away from moving parts.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Spare parts Only use CNH Original Parts.

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

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

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

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

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

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

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

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

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

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

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

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

WARNING Battery acid causes burns. Batteries contain sulfuric acid.

Avoid contact with skin, eyes or clothing. Antidote (external): Flush with water. Antidote (eyes): flush with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large quantities of water or milk. Do not induce vomiting. Seek medical attention immediately.

Failure to comply could result in death or serious injury.

W0111A

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

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

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

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

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

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

There are two types of contamination: microscopic and visible.

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

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

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

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

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

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

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

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

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

Always wear eye protection when working with batteries.

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

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

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

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

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

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

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

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

• Use torque wrenches for tightening.

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

Thread size

M6 M8 M8x1 M10 M10x1.25 M12 M12x1.25 M14 M14x1.5 M16 M16x1.5 M18 M18x1.5 M20 M20x1.5 M22 M22x1.5 M24 M24x2 M27 M27x2 M30 M30x2

TIGHTENING TORQUE For screws 8.8 (8G) 10 N·m (7.4 lb ft) 24 N·m (17.7 lb ft) 19 N·m (14.0 lb ft) 48 N·m (35.4 lb ft) 38 N·m (28.0 lb ft) 83 N·m (61.2 lb ft) 66 N·m (48.7 lb ft) 132 N·m (97.4 lb ft) 106 N·m (78.2 lb ft) 200 N·m (147.5 lb ft) 160 N·m (118.0 lb ft) 275 N·m (202.8 lb ft) 220 N·m (162.3 lb ft) 390 N·m (287.6 lb ft) 312 N·m (230.1 lb ft) 530 N·m (390.9 lb ft) 425 N·m (313.5 lb ft) 675 N·m (497.9 lb ft) 540 N·m (398.3 lb ft) 995 N·m (733.9 lb ft) 795 N·m (586.4 lb ft) 1350 N·m (995.7 lb ft) 1080 N·m (796.6 lb ft)

For srews 10.9 (10K) 14 N·m (10.3 lb ft) 34 N·m (25.1 lb ft) 27 N·m (19.9 lb ft) 67 N·m (49.4 lb ft) 54 N·m (39.8 lb ft) 117 N·m (86.3 lb ft) 94 N·m (69.3 lb ft) 185 N·m (136.4 lb ft) 148 N·m (109.2 lb ft) 285 N·m (210.2 lb ft) 228 N·m (168.2 lb ft) 390 N·m (287.6 lb ft) 312 N·m (230.1 lb ft) 550 N·m (405.6 lb ft) 440 N·m (324.5 lb ft) 745 N·m (549.5 lb ft) 590 N·m (435.2 lb ft) 950 N·m (700.7 lb ft) 760 N·m (560.5 lb ft) 1400 N·m (1032.6 lb ft) 1120 N·m (826.0 lb ft) 1900 N·m (1401.4 lb ft) 1520 N·m (1121.1 lb ft)

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

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

Thread size

Hose

14

12x1.5

6

17

14x1.5

8

19

16x1.5

22

18x1.5

24

20x1.5

12

27

22x1.5

14 15

30

24x1.5

16

32

26x1.5

18

8 10 10 12

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

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INTRODUCTION

Size wrench

Thread size

36

30x2

41 46

36x2

50

42x2

30

45x2

35

52x2

38 42

50

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

Hose 20 22 25 28

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

Tightening torques for flanges 25 N·m (18 lb ft) 40 N·m (30 lb ft) 95 N·m (70 lb ft) 130 N·m (96 lb ft) 250 N·m (184 lb ft) 400 N·m (295 lb ft) 600 N·m (443 lb ft) 800 N·m (590 lb ft)

10 x 1 12 x 1.5 14 x 1.5 16 x 1.5 18 x 1.5 20 x 1.5 22 x 1.5 26 x 1.5 27 x 1.5 33 x 1.5 42 x 1.5 48 x 1.5

25 N·m (18 lb ft) 30 N·m (22 lb ft) 50 N·m (37 lb ft) 60 N·m (44 lb ft) 60 N·m (44 lb ft) 140 N·m (103 lb ft) 140 N·m (103 lb ft) 220 N·m (162 lb ft) 250 N·m (184 lb ft) 400 N·m (295 lb ft) 600 N·m (443 lb ft) 800 N·m (590 lb ft)

SS12C493

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INTRODUCTION

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

Tightening torques for flanges 15 N·m (11 lb ft) 33 N·m (24 lb ft) 70 N·m (52 lb ft) 90 N·m (66 lb ft) 150 N·m (111 lb ft) 220 N·m (162 lb ft) 600 N·m (443 lb ft) 800 N·m (590 lb ft)

10 x 1 12 x 1.5 14 x 1.5 16 x 1.5 18 x 1.5 20 x 1.5 22 x 1.5 26 x 1.5 27 x 1.5 33 x 1.5 42 x 1.5 48 x 1.5

13 N·m (10 lb ft) 30 N·m (22 lb ft) 40 N·m (30 lb ft) 60 N·m (44 lb ft) 70 N·m (52 lb ft) 90 N·m (66 lb ft) 100 N·m (74 lb ft) 120 N·m (89 lb ft) 150 N·m (111 lb ft) 250 N·m (184 lb ft) 400 N·m (295 lb ft) 500 N·m (369 lb ft)

SS12K194

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INTRODUCTION

Torque - Standard torque data for hydraulics INSTALLATION OF ADJUSTABLE FITTINGS IN STRAIGHT THREAD O RING BOSSES 1. Lubricate the O-ring by coating it with a light oil or petroleum. Install the O-ring in the groove adjacent to the metal backup washer which is assembled at the extreme end of the groove (4).

2. Install the fitting into the SAE straight thread boss until the metal backup washer contacts the face of the boss (5).

NOTE: Do not over tighten and distort the metal backup washer.

23085659

1

3. Position the fitting by turning out (counterclockwise) up to a maximum of one turn. Holding the pad of the fitting with a wrench, tighten the locknut and washer against the face of the boss (6).

STANDARD TORQUE DATA FOR HYDRAULIC TUBES AND FITTINGS TUBE NUTS FOR 37° FLARED FITTINGS

SIZE

TUBING OD

THREAD SIZE

TORQUE

O-RING BOSS PLUGS ADJUSTABLE FITTING LOCKNUTS, SWIVEL JIC- 37° SEATS TORQUE

4 5 6 8 10 12 14 16 20 24 32

6.4 mm (1/4 in) 7.9 mm (5/16 in) 9.5 mm (3/8 in) 12.7 mm (1/2 in) 15.9 mm (5/8 in) 19.1 mm (3/4 in) 22.2 mm (7/8 in) 25.4 mm (1 in) 31.8 mm (1-1/4 in) 38.1 mm (1-1/2 in) 50.8 mm (2 in)

7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1-1/16-12 1-3/16-12 1-5/16-12 1-5/8-12 1-7/8-12 2-1/2-12

12 - 16 N·m (9 - 12 lb ft) 16 - 20 N·m (12 - 15 lb ft) 29 - 33 N·m (21 - 24 lb ft) 47 - 54 N·m (35 - 40 lb ft) 72 - 79 N·m (53 - 58 lb ft) 104 - 111 N·m (77 - 82 lb ft) 122 - 136 N·m (90 - 100 lb ft) 149 - 163 N·m (110 - 120 lb ft) 190 - 204 N·m (140 - 150 lb ft) 217 - 237 N·m (160 - 175 lb ft) 305 - 325 N·m (225 - 240 lb ft)

8 - 14 N·m (6 - 10 lb ft) 14 - 20 N·m (10 - 15 lb ft) 20 - 27 N·m (15 - 20 lb ft) 34 - 41 N·m (25 - 30 lb ft) 47 - 54 N·m (35 - 40 lb ft) 81 - 95 N·m (60 - 70 lb ft) 95 - 109 N·m (70 - 80 lb ft) 108 - 122 N·m (80 - 90 lb ft) 129 - 158 N·m (95 - 115 lb ft) 163 - 190 N·m (120 - 140 lb ft) 339 - 407 N·m (250 - 300 lb ft)

These torques are not recommended for tubes of 12.7 mm (1/2 in) OD and larger with wall thickness of 0.889 mm (0.035 in) or less. The torque is specified for 0.889 mm (0.035 in) wall tubes on each application individually.

Before installing and torquing 37 ° flared fittings, clean the face of the flare and threads with a clean solvent or Loctite cleaner and apply hydraulic sealant LOCTITE® 569 to the 37 ° flare and the threads.

Install fitting and torque to specified torque, loosen fitting and retorque to specifications.

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INTRODUCTION

PIPE THREAD FITTING TORQUE

PIPE THREAD FITTING

Before installing and tightening pipe fittings, clean the threads with a clean solvent or Loctite cleaner and apply sealant LOCTITE® 567 PST PIPE SEALANT for all fittings including stainless steel or LOCTITE® 565 PST for most metal fittings. For high filtration/zero contamination systems use LOCTITE® 545.

Torque (Maximum) 13 N·m (10 lb ft) 16 N·m (12 lb ft) 22 N·m (16 lb ft) 41 N·m (30 lb ft) 54 N·m (40 lb ft)

Thread Size 1/8-27 1/4-18 3/8-18 1/2-14 3/4-14

INSTALLATION OF ORFS (O-RING FLAT FACED) FITTINGS When installing ORFS fittings thoroughly clean both flat surfaces of the fittings (1) and lubricate the O-ring (2) with light oil. Make sure both surfaces are aligned properly.

Torque the fitting to specified torque listed throughout the repair manual.

NOTICE: If the fitting surfaces are not properly cleaned, the O-ring will not seal properly. If the fitting surfaces are not properly aligned, the fittings may be damaged and will not seal properly.

NOTICE: Always use genuine factory replacement oils and filters to ensure proper lubrication and filtration of engine and hydraulic system oils.

The use of proper oils, grease, and keeping the hydraulic system clean will extend machine and component life.

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50011183

2

INTRODUCTION

Basic instructions - Shop and assembly Shimming For each adjustment operation, select adjusting shims and measure the adjusting shims individually using a micrometer, then add up the recorded values. Do not rely on measuring the entire shimming set, which may be incorrect, or the rated value shown on each shim.

Rotating shaft seals For correct rotating shaft seal installation, proceed as follows: 1. Before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes.

2. Thoroughly clean the shaft and check that the working surface on the shaft is not damaged.

3. Position the sealing lip facing the fluid.

NOTE: With hydrodynamic lips, take into consideration the shaft rotation direction and position the grooves so that they will move the fluid towards the inner side of the seal.

4. Coat the sealing lip with a thin layer of lubricant (use oil rather than grease). Fill the gap between the sealing lip and the dust lip on double lip seals with grease.

5. Insert the seal in its seat and press down using a flat punch or seal installation tool. Do not tap the seal with a hammer or mallet.

6. While you insert the seal, check that the seal is perpendicular to the seat. When the seal settles, make sure that the seal makes contact with the thrust element, if required.

7. To prevent damage to the seal lip on the shaft, position a protective guard during installation operations.

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

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

Spare parts Only use CNH Original Parts or CASE CONSTRUCTION Original Parts.

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

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

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INTRODUCTION

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

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

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

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

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

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

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

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

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

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

WARNING Battery acid causes burns. Batteries contain sulfuric acid.

Avoid contact with skin, eyes or clothing. Antidote (external): Flush with water. Antidote (eyes): flush with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large quantities of water or milk. Do not induce vomiting. Seek medical attention immediately.

Failure to comply could result in death or serious injury.

W0111A

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

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

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INTRODUCTION

Special tools Jigs – Engine No. 1: Handling (65-374-182) – lifting lug

SS12N754

1

SS12N781

2

SS12N062

3

SS13A042

4

No. 2: Handling (64-373-0140) – lifting lug, screw tightener

Jigs – Edge cutter No. 1: Wrench for nut KM 10 (part no. 92-655-0056)

Jigs – Steering No. 1: Assembly tool (64-374-0112) – to remove the steering wheel

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INTRODUCTION

No. 2: Spanner to remove cover 10 (92-655-0092), (92655 0094)

SS13A043

5

SS13A044

6

SS13A135

7

SS12N740

8

No. 3: Guide bush 92-644-031

No. 4: Checking tool (64-374-281)

Jigs – Rear axle No. 1: (4-05103A), No. 2 (4-05102A) Installation tools (supplied as machine accessories) – to brake off the machine

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INTRODUCTION

No. 3: Installation tool (64-363-0114) – to stabilize casings (1, 2) in vertical position

SS13A032

9

No. 4: Handling tool (64-374-0111) – lifting lug by flange of differential

SS13A034

10

SS12N063

11

SS12N061

12

No. 5: Socket driver (92-655-056) for nut KM 14

No. 6: Stamping tool (64-374-414) for bearing 27

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INTRODUCTION

Jigs – Front axle No. 1: Handling tool (65-424-121) – lifting lug to remove/ install front axle

SS13A137

13

SS13A130

14

SS13A136

15

SS13A128

16

No. 2: Installation stand (4761 009) AXL- to remove front axle – packing material

No. 3: Handling tool (65-424-044) – lifting lug – to handle front axle

No. 4: Handling tool (3139 049) AXL – universal joint wrench for face holes

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INTRODUCTION

No. 5: Checking tool (4851 017) AXL – for pressure test

SS13A131

17

SS13A132

18

SS13A133

19

SS13A129

20

No. 6: Handling tool (7443 022) AXL – to handle front axle

No. 7: Pressing tool (64-374-261) – for outer ring of bearing 9

No. 8: Pressing tool (92-631-0117) – for oil seal 11

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INTRODUCTION

No. 9: Installation stand (64-374-276)

SS13A134

21

SS12N439

22

SS13A139

23

SS13A138

24

No. 10: Pressing tool (92-631-006) - for inner ring of bearing 9 NOTE: When ordering the jig, use the measurement 70.00 mm (2.76 in) / 63.00 mm (2.48 in) - 200.00 mm (7.87 in).

No. 11: Handling tool (64-374-0004) – for oil seal

No. 12: Adapter to for final tightening of KM nuts (64-3730461)

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INTRODUCTION

No. 13: Assembly tool (92-631-006) - to press the bearings (ø 105.00 mm (4.13 in) / ø 85.00 mm (3.35 in) x 120.00 mm (4.72 in))

SS12N439

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25

INTRODUCTION

General specification

SS12D597

1

Instruments and controls

(1) Ignition switch In the 0 position, the machine lighting will be connected along with hand lamp socket. In the I position, other consumers will be connected. Spring-loaded position II is used to start the engine. The key can be removed in the 0 position only.

(2) Travel controller The controller is used to adjust the running direction and to shift gears via a turning handle.

F position - forward N position - idle (neutral) R position - reverse The horn button and switch are part of the controller.

Position of N switch - controller blocking.

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INTRODUCTION

(3) Tire inflation, (4) Tire deflation These are used to inflate or deflate the tires with air.

NOTE: Do not switch ON both valves simultaneously to I position.

(5) Transmission fluid pressure gauge The transmission fluid pressure must be within the range 12.5 - 15.5 bar (181.25 - 224.75 psi).

NOTE: When pressure drops below 12.5 bar (181.25 psi), stop the machine.

(6) Transmission fluid temperature The operating temperature must be within the range 80 - 120 °C (176 - 248 °F). The maximum temperature is 120 °C (248 °F).

(7) Multifunctional display Multifunctional instrument for displaying engine function and fuel reading.

SS13G029

2

Instruments and controls

(8) Brake circuit pressure gauge The white indicator shows air pressure inside the air reservoir. Adjusted to the maximum = 8 bar (116 psi). The red one indicates air pressure when braking. Air pressure from the air brake valve to the brake booster.

(9) Tire pressure gauge The minimum air pressure after air release from tires has been adjusted to 1.5 - 2 bar (21.75 - 29 psi).

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INTRODUCTION

(10) Emergency stop Press to stop the machine and engine instantly in the event of an emergency.

(11) Active working position Indicates from which position (seat) the roller travel is controlled. If no indicator lamp (11) flashes when the ignition switch is turned ON, then the engine can be started. If the indicator lamps (11) flash when the ignition switch is turned ON, then the engine cannot be started since one or two travel controllers are not in the “N” position - idle indicator lamp does not light.

(12) Sprinkling switch and interval control Turn the switch left to set the pump to run continuously. The tires will be sprinkled constantly. Turn the switch to any of four positions in a clockwise direction to turn the sprinkling interval control ON. Position I II III IV

Sprinkling for 10 s 10 s 10 s 10 s

Stop for 10 s 15 s 22 s 33 s

NOTE: The sprinkling indicator lamp is only lit when the pump is running.

(13) Engine Control Module (ECM) diagnostics socket For connecting to the Engine Control Module (ECM). Designed to diagnose any defects or to adjust engine parameters.

SS12D606

3

Instruments and controls

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INTRODUCTION

Battery recharging Goes OFF when engine is started.

Parking brake Indicates the brake is engaged.

Engine heating Indicates the engine is warming up.

Hydraulic oil filter restriction Indicates the filter element must be replaced.

Idle Indicates that both travel controllers are in the neutral N idle position.

Direction indicators LED lamp ON enabled workstation will light.

Hydraulic oil level Indicates low level.

NOTE: When there is an alarm, the roller stops and the engine switches OFF. Starting is blocked until oil is filled up.

Brake failure Indicates air pressure in the circuit is below 5.2 bar (75.40 psi), simultaneously with an audible alarm.

Hydraulic oil overheated Indicates maximum permitted temperature exceeded (reduce power, cool down).

Air filter restriction Indicates the filter element must be replaced.

Tire sprinkling Sprinkling pump turned ON.

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INTRODUCTION

SS13F354

4

Instruments and controls

Headlights Incl. fender lights

Tail lights

Hazard warning lights Hazard warning beacon (option)

Differential lock (option).

Parking brake

Edge cutter Downward and upward (option).

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INTRODUCTION

Idle switch For engine start.

Directions indicators

Multifunctional display

SS12N052

5

Multifunctional display 1 2 3 4 5 6 7

Warning light – yellow LED lights Alarm for engine failure or minimal fuel level in tank Engine shut-off light – red LED lights Alarm for major engine malfunction Enter button Selects Menu or parameter, or conceals/displays active error code Right/up navigation button - to move cursor DOWN Illuminates data on the display or moves the parameter option to the right or down Left/down navigation button - to move cursor UP Illuminates data on the display or moves the parameter option to the left or up Menu selection button - to enter or exit Menu Display screen

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INTRODUCTION

General specification NOTICE: While any company can perform the necessary maintenance or repairs on your equipment, CASE CONSTRUCTION strongly recommends that you use only 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.

CASE CONINTERNATIONAL STRUCRECOMMENDED FLUIDS MODELS QUANTITY Specifications TIONSpecifiAND APPLICATION cations ENGINE - OIL Recommended oil: All seasons: CASE AKCELA SAE 15W - 40 NO. 1™ ENGINE OIL SAE SAE 10W - 30 15W-40 SAE 5W30 7 L (1.85 US gal) ALL MAT 3507 Winter: CASE AKCELA API CF-4 NO. 1™ ENGINE OIL SAE API CI4 10W-30 API CJ-4 Extreme cold weather TUTELA AUTO SUPREME™ ENGINE OIL SAE 5W-30 COOLING SYSTEM ASTM D6210 Type CNH XHD HEAVY DUTY 11.5 L (3.04 US gal) ALL 1-FF COOLANT / ANTI-FREEZE antifreeze 50% water 50% HYDRAULIC SYSTEM API GL-4 CASE AKCELA HY-TRAN® 22 L (5.81 US gal) MAT 3505 ALL SAE 10W - ISO ULTRA™ HYDRAULIC VG-46 TRANSMISSION OIL TRANSMISSION FLUID: Automatic transmission 21.5 L (5.68 US gal) AUTOMATIC TRANSMIS6 L (1.59 US gal) Final drive and differential SION: CASE AKCELA ATF Automatic NOTE: Never Use Engine oil, Transmission: DEXRON III or other transSAE 10W mission fluids for Automatic DEXRON II transmission Differential: API 2 X 5.2 L (1.37 US FINAL DRIVE GL-5 Rear axle gal) CASE AKCELA GEAR 135 SAE 80W - 90 H EP 80W-90 Speed reduction: SPEED REDUCTION SAE 85W140 TRANSMISSION: CASE AKCELA GEAR 135 H EP 85W-140 FUEL TANK Ultra Low Sulfur Diesel (ULSD) SAE ASTM EN590 250 L (66.04 US gal) ALL Decanted and filtered diesel ASTM D975 fuel (Sulfur not exceeding 15 mg/kg) STEERING JOINT BEARINGS, YOKE BEARINGS, STEERING SWIVEL PINS, SUSPENSIONS: TUTELA MULTI -PURPOSE EP As required MAT 3550 ALL NLGI 2 GREASE 251H, GR-9 NOTE: To lubricate the speed reduction transmission, use the lubricant according to: ISO 6743/9 BDHB2 47703681 09/09/2015

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INTRODUCTION

ALL

GLASS WASHER TANK SPRINKLING TANK

Water

–

ALL

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

ALL SAE J1703 SAE J1704 ISO 4925 NHTSA 116-DOT 4

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2.5 L (0.66 US gal) 460 L (121.52 US gal) Contact your dealer

1.75 L (0.46 US gal)

INTRODUCTION

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

Performance classification under: American Petroleum Institute (API)

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

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

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

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

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

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

NOTICE: Do not allow the upper temperature limit to be exceeded for long periods of time as this will reduce the capabilities of the oil. When using oil API CG-4/SH, the oil change interval must be reduced by half, i.e. 125 h.

SS12C358

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1

INTRODUCTION

Fuel

WARNING Fire hazard!

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

Fuel combinations may increase fire and explosion hazards.

Failure to comply could result in death or serious injury.

W0401A

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

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

Coolant

WARNING Chemical hazard!

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

Failure to comply could result in death or serious injury.

W1109A

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

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

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

NOTICE: Do not use coolant with an antifreeze concentration greater than 50 %. The coolant will begin to gel or solidify at -36 °C (-33 °F) and the boiling point is 110 °C (230 °F), unless absolutely required.

Never use an antifreeze concentration over 68 %!

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

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

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

Fill the machine with hydraulic oil of cinematic viscosity 68 mm 2 / s at 40 °C (104 °F), i.e. ISO VG 68. This oil is most appropriate for use within the widest range of ambient temperatures.

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

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

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INTRODUCTION

Automatic transmission fluid Use the following lubricants for the automatic transmission: SAE 10W-20 DEXRON II NOTICE: Never use engine oils, transmission fluids or DEXRON III. With normal ambient temperature, please use multigrade oil of low viscosity value 10W-20 as if low-grade oil 10W was used.

Synthetic oil has been approved for use for transmissions if it corresponds to the specifications above.

For areas with an ambient temperature characterized as tropic, we recommend use of transmission fluid with a viscosity value of SAE 30.

Transmission fluid

Final Drive Use CASE AKCELA GEAR 135 H EP 80W-90 fluid to lubricate the final drive.

Speed reduction transmission Use CASE AKCELA GEAR 135 H EP 85W-140 fluid to lubricate speed reduction transmission.

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

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

Lube grease Use plastic lubricant with lithium content to lubricate the machine: TUTELA MULTI -PURPOSE EP GREASE 251H, GR-9 To lubricate the speed reduction transmission, use the lubricant according to: ISO 6743/9 BDHB2

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

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

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INTRODUCTION

Product identification PT240

LA --- NA ---

Write your machine model number, Product Identification Number (PIN), and serial numbers on the lines provided below. Always give these numbers and component plate numbers to your dealer when you need parts or information for your machine.

Make a record of the numbers. Keep this record and your manufacturers statement of origin in a safe place. If the machine is stolen, report the numbers to your local law enforcement agency.

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

RAIL14COM0348BA

Pos. 1 2

Designation Production label Product Identification Number (PIN)

SS12D571

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2

1

INTRODUCTION

Part identification PT240

LA --- NA ---

SS13G020

Pos. Designation 1 Roller frame 2 Engine 3 Engine radiator, hydraulic circuit cooler, and transmission cooler 4 Transmission including torque converter 5 Final drive housing including differential 6 Final transmissions 7 Propeller shaft 8 Parking and emergency brake 9 Service brake (rear wheels only) 10 Front axle including telescopic cylinders 11 Compressor drive pump 12 Power steering 13 Battery (left side of cylinder)

1

Pos. Designation 14 Hydraulic tank (right side of cylinder) 15 *Additional water weight closure 16 Fuel tank 17 18 19 20 21 22 23 24 25

Operator’s control stand Sprinkling tank Tire sprinkling Wheels Scrapers Roll Over Protective Structure (ROPS) frame Additional weight Ballast space lids Additional water weight drain

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INTRODUCTION

Product identification PT240

LA --- NA ---

As used in this manual, the terms right, left, front, and rear indicate the sides of the machine as seen from the operator’s seat.

SS12D573

Pos. A Front B Rear

Designation

1

Pos. C Left D Right

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Designation

SERVICE MANUAL Engine PT240

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Contents Engine - 10

[10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

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Engine - 10 Fan and drive - 414

PT240

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Contents Engine - 10 Fan and drive - 414

SERVICE Belt Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - Fan and drive

Belt - Replace WARNING Hot surface possible!

Wait for all components to cool before performing any operation.

Failure to comply could result in death or serious injury.

W0251A

1. Stop the engine.

2. Loosening the bolt for the alternator holder (1) and tensioning arm (2).

3. Push the alternator towards the engine.

4. Remove the old belt, and install the new belt.

SS12E056

1

SS12E055

2

SS12E056

3

5. Using your hand, press the belt in the longest spot between pulleys ( 30.00 cm (11.81 in) ) with approximately 110 N (25 lb) of force.

6. If slack (X) is excessive, tighten the belt by pulling the alternator away from the engine.

7. Once the belt tightness is within specification (see image 2), torque bolt (1) to 66 N·m (49 lb ft) and torque bolt (2) to 31 N·m (23 lb ft).

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Index Engine - 10 Fan and drive - 414 Belt - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - 10 Engine cooling system - 400

PT240

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Contents Engine - 10 Engine cooling system - 400

SERVICE Radiator Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - Engine cooling system

Radiator - Drain fluid 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

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

SS12C364

1

SS12E041

2

SS12E080

3

1. Remove the expansion tank cap.

2. Remove the plug.

3. Drain approximately 11.5 L (3 US gal) of coolant into an adequate container.

4. Reinstall the drain plug. Tighten to 80 N·m (59 lb ft).

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Index Engine - 10 Engine cooling system - 400 Radiator - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - 10 Engine and crankcase - 001

PT240

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Contents Engine - 10 Engine and crankcase - 001

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

SERVICE Engine Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

DIAGNOSTIC Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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Engine - Engine and crankcase

Engine - Component identification

SS12N065

1

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Engine - Engine and crankcase

Position 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

Designation Beam Holder Holder Holder Bracket Coupling Clamp Holder Holder Filter holder Filter holder Steel plate Pipe Pipe Pipe Pipe Connecting pipe Reducing piece Spacer ring Cube Washer Elbow Bracket Engine adapter Hose Hose Hose Hose Hose Holder Cummins engine Cooler Compressor Hydraulic pump Clip Pump

Position 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 59 60 61 62 63 64 65 66 67 69 70 71 72 73 74 76

Designation Safety valve Equalizer tank Silent block Elbow Elbow Elbow Elbow Reducing piece Terminal Terminal Couplin Hose Hose Hose Connecting pipe Connecting pipe Hose clamp Hose clamp Hose clamp Hose clamp Hose clamp Clip Clip Ring Ring Spring washer Washer Washer for wood Washer Spring washer Washer Washer Washer Washer Nut Washer

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Position 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 101 102 103 104 105 106 107 108 115 116 117 118 119

Designation Washer Washer Lock nut Nut Nut Nut Nut Nut Stud bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Stud bolt Bolt Bolt Bolt Bolt Bolt Stud bolt Bolt Bolt Bolt Bolt Bolt Terminal Connecting pipe Hose clamp Plug Gasket Plug Connecting pipe

Engine - Engine and crankcase

SS12N064

2

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Engine - Engine and crankcase

Position 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

Designation Beam Holder Holder Holder Bracket Coupling Clamp Holder Holder Filter holder Filter holder Steel plate Pipe Pipe Pipe Pipe Connecting pipe Reducing piece Spacer ring Cube Washer Elbow Bracket Engine adapter Hose Hose Hose Hose Hose Holder Cummins engine Cooler Compressor Hydraulic pump Clip Pump

Position 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 59 60 61 62 63 64 65 66 67 69 70 71 72 73 74 76

Designation Safety valve Equalizer tank Silent block Elbow Elbow Elbow Elbow Reducing piece Terminal Terminal Couplin Hose Hose Hose Connecting pipe Connecting pipe Hose clamp Hose clamp Hose clamp Hose clamp Hose clamp Clip Clip Ring Ring Spring washer Washer Washer for wood Washer Spring washer Washer Washer Washer Washer Nut Washer

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Position 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 101 102 103 104 105 106 107 108 115 116 117 118 119

Designation Washer Washer Lock nut Nut Nut Nut Nut Nut Stud bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Stud bolt Bolt Bolt Bolt Bolt Bolt Stud bolt Bolt Bolt Bolt Bolt Bolt Terminal Connecting pipe Hose clamp Plug Gasket Plug Connecting pipe

Engine - Engine and crankcase

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

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Engine - Engine and crankcase

Engine - Drain fluid 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 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

1. Remove the drain plug and let the oil flow out into a container with a capacity of approximately 9 L (2.38 US gal).

2. Reinstall the drain plug. Tighten to 80 N·m (59 lb ft).

SS12E015

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1

Engine - Engine and crankcase

Engine - Remove Prior operation: Remove the water tank.

Prior operation: Remove the front cover and hood.

Prior operation: Remove the cab.

Prior operation: Remove the front panel.

Prior operation: Remove the ROPS (refer to Operator protections - Remove (90.114)).

NOTE: For more details, refer to Engine - Component identification (10.001).

1. Drain the engine oil.

SS12N070

1

SS12N071

2

SS12N072

3

2. Drain the coolant.

3. Drain the transmission fluid.

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Engine - Engine and crankcase

4. Drain the hydraulic oil.

SS12N073

4

SS12N376

5

SS12N377

6

SS12N378

7

5. Remove the bolts connecting the shaft to the transmission.

6. Detach the hydraulic oil hoses.

7. Remove the pump discharge hose.

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Engine - Engine and crankcase

8. Remove and plug the suction hose.

SS12N379

8

SS12N380

9

9. Remove the compressor suction hose.

10. Remove the engine air intake pipe.

SS12N381

10

SS12N382

11

11. Disconnect the vacuum switch connectors.

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Engine - Engine and crankcase

12. Remove the covers along both sides.

SS12N383

12

SS12N384

13

SS12N385

14

SS12N386

15

13. Remove the air filter holder brackets.

14. Remove the filter.

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Engine - Engine and crankcase

15. Remove the heater hose – left-hand side.

SS12N387

16

SS12N388

17

SS12N389

18

SS12N390

19

16. Remove the heater hose – right-hand side.

17. Remove the pipe running from the compressor to the radiator.

18. Remove the hydraulic pump pipe for the compressor drive.

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Engine - Engine and crankcase

19. Disconnect the contactor wiring; mark it according to the wiring diagram.

SS12N391

20

SS12N392

21

SS12N393

22

SS12N394

23

20. Disconnect the transmission air temperature sensor.

21. Disconnect the transmission pressure sensor.

22. Disconnect the control unit wiring.

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Engine - Engine and crankcase

23. Disconnect the ground connection.

SS12N395

24

SS12N396

25

SS12N397

26

SS12N398

27

24. Disconnect the starter wiring.

25. Disconnect the alternator wiring; put the strips away.

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Engine - Engine and crankcase

26. Remove the pump hose.

SS12N399

28

SS12N400

29

SS12N321

30

SS12N322

31

27. Remove the fuel supply.

28. Remove the fuel overflow from the fuel injection pump.

29. Remove the pipe used to drain the fluid from the transmission.

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Engine - Engine and crankcase

30. Remove the front engine mount.

SS12N323

32

SS12N324

33

SS12N325

34

SS12N081

35

31. Remove the rear engine mount.

32. Remove the pipes from the radiator.

33. Install a jig.

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Engine - Engine and crankcase

34. Fix a rope and a chain’s strand to the cooler case.

NOTE: To lift the engine, use a shortening chain (toggle), e.g. Gunnebo.

SS12N759

36

SS12N760

37

SS12N080

38

SS12N201

39

35. Fix the next chain strand to a jig, and to the loops of the engine.

36. Adjust the individual strand of the chain so that the engine does not deviate from the vertical axis and horizontal axis when being lifted. It is only necessary to lift the engine slightly for the next removal operations.

NOTE: When handling, please pay attention to avoid any damage to the radiator or cooling fan.

37. With the engine lifted slightly, remove the hydraulic oil hose.

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Engine - Engine and crankcase

38. Then disconnect the engine oil drain pipe.

SS12N202

40

SS12N203

41

39. Mark and disconnect the wiring for the Clark transmission.

Start lifting slowly while checking all hoses and wiring disconnected from the engine. Lay the engine aside on a proper pedestal and secure against any overturning.

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Engine - Engine and crankcase

Engine - Install NOTE: For more details, refer to Engine - Component identification (10.001).

1. Slowly lower the engine into position.

2. Connect the wiring for the transmission.

SS12N203

1

SS12N202

2

SS12N201

3

SS12N325

4

3. Connect the engine oil drain pipe.

4. Connect the hydraulic oil hose.

5. Install the pipes to the radiator.

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Engine - Engine and crankcase

6. Install the rear engine mount.

NOTE: When installing, level and mount the engine. Glue the nuts of rubber mountings with LOCTITE® 567™ PST PIPE SEALANT. Tighten the nuts; refer to Torque ().

SS12N324

5

SS12N323

6

SS12N322

7

SS12N321

8

7. Install the front engine mount.

8. Install the pipe used to drain the fluid from the transmission.

9. Install the fuel overflow to the fuel injection pump.

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Engine - Engine and crankcase

10. Install the fuel supply.

SS12N400

9

11. Install the pump hose.

SS12N399

10

SS12N397

11

SS12N398

12

12. Connect the alternator wiring.

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Engine - Engine and crankcase

13. Connect the starter wiring.

SS12N396

13

SS12N395

14

SS12N394

15

SS12N393

16

14. Connect the ground connection.

15. Connect the control unit wiring.

16. Connect the transmission pressure sensor.

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Engine - Engine and crankcase

17. Connect the transmission air temperature sensor.

SS12N392

17

SS12N391

18

SS12N390

19

SS12N389

20

18. Connect the contactor wiring.

19. Remove the hydraulic pump pipe for the compressor drive.

20. Install the pipe running from the compressor to the radiator.

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Engine - Engine and crankcase

21. Install the heater hose – right-hand side.

SS12N388

21

SS12N387

22

SS12N386

23

22. Install the heater hose – left-hand side.

23. Install the filter.

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Engine - Engine and crankcase

24. Install the air filter holder brackets.

SS12N384

24

SS12N385

25

SS12N383

26

SS12N382

27

25. Install the covers along both sides.

26. Connect the vacuum switch connectors.

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Engine - Engine and crankcase

27. Install the engine air intake pipe.

SS12N381

28

SS12N380

29

SS12N379

30

SS12N378

31

28. Install the compressor suction hose.

29. Install the suction hose.

30. Install the pump discharge hose.

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Engine - Engine and crankcase

31. Attach the hydraulic oil hoses.

SS12N377

32

SS12N376

33

32. Install the bolts connecting the shaft to the transmission.

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Engine - Engine and crankcase

Engine - Troubleshooting Problem Engine does not start; starter does crank

Possible Cause Empty fuel tank

Correction Refill fuel and bleed fuel system if required.

Leakage, air pocket in fuel system

• Check and remedy leaking connections.

• Refill fuel via hand pump.

• Coarse-meshed fuel filter – filters and lines • clogged with dirt • Coarse-meshed fuel filter – filters and lines • clogged with paraffin deposits during winter • season • Oil used too dense during winter season •

Bleed the fuel system.

Clean up the fuel filter, lines.

Replace the filters.

Clean up the fuel filter, lines.

Replace the filters.

Change the fuel.

Use appropriate oil for given temperature.

Wiring not connected – indicator lights do Connect any disconnected wiring.

Engine does not start; starter does not crank or not light cranks slowly Travel controller not in neutral – neutral in- Shift controller to neutral. dicator light does not light Terminals, starter cables, ground cable, • Retighten terminals, clean, and (oxidation, loosened, faulty battery) preserve.

• Check the starter cables.

• Check the ground cable.

Engine overheats

Engine runs irregularly with low power.

• Check the battery condition (electrolyte level, density).

Starter Check pinion engagement and disengagement (function of electromagnetic coil).

Starter relay Check the cables and test its switching.

Engine electric stop Check the cables and confirm functionality.

Insufficient coolant in cooling circuit.

Stop engine instantly, refill coolant, find cause of leakage, repair leakage.

Engine radiator clogged with contaminants. Remove the contaminants.

Defective engine tensioning device or belt Repair/replace the belt. broken.

Thermostat does not work properly.

• Test whether thermostat works.

• Replace if necessary.

High amount of dirt and deposits in cooling Clean the cooling circuit. circuit.

Defective injection nozzles.

Contact your authorized engine dealer to check.

Incorrect amount of fuel supplied by injec- Contact your authorized engine dealer to tion pump. adjust.

External temperature too high.

Operate for limited period of time and let engine cool down.

Fuel injection timing incorrectly adjusted. Contact your authorized engine dealer to check.

Air pocket in the fuel system.

• Bleed the system.

Defective injection nozzles Incorrect valve clearance Injection pipe broken Injection pump incorrectly adjusted

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• Repair the leaks.

Contact your authorized check.

Contact your authorized check.

Contact your authorized check.

Contact your authorized check.

engine dealer to engine dealer to engine dealer to engine dealer to

Engine - Engine and crankcase

Problem Engine smokes excessively

Possible Cause Increased vacuum in engine air intake

Correction • Check if vacuum switch works.

• Replace inserts if required.

Engine oil level too high Reduce the level to upper mark on dipstick.

Incorrect compression due to burned or • Have piston rings and pistons tested by broken piston rings or incorrect valve clear- authorized engine dealer. ance.

• Adjust the valve clearance.

High oil consumption Leaking oil system Repair the leaks.

Leaking piston rings or overall engine wear Contact your authorized engine dealer to and tear inspect.

Insufficient engine power. Fuel filter excessively contaminated Replace the filters.

Incorrect valve clearance Adjust the valve clearance.

Clogged injection nozzle holes; injectors Contact your authorized engine dealer to not adjusted to correct pressure. inspect.

Injection pump incorrectly adjusted Contact your authorized engine dealer to inspect.

Fuel injection advance incorrectly adjusted Contact your authorized engine dealer to inspect.

Cylinders have incorrect compression Contact your authorized engine dealer to pressure inspect.

Thermostat does not work properly Contact your authorized engine dealer to inspect.

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Index Engine - 10 Engine and crankcase - 001 Engine - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Engine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Engine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Engine - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Engine - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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

PRINTED IN U.S.A. © 2015 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

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

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

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SERVICE MANUAL Transmission PT240

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Contents Transmission - 21

[21.118] Transmission/Rear drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1

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Transmission - 21 Transmission/Rear drive - 118

PT240

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Contents Transmission - 21 Transmission/Rear drive - 118

SERVICE Transmission/Rear drive Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Mechanical transmission - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

DIAGNOSTIC Transmission/Rear drive Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Transmission - Transmission/Rear drive

Transmission/Rear drive - Drain fluid 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 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

1. Remove the plug, and drain the fluid into a suitable container that holds 21.5 L (5.7 US gal) of fluid.

2. Reinstall the drain plug. Tighten to 80 N·m (59 lb ft).

SS12E057

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1

Transmission - Transmission/Rear drive

Mechanical transmission - Remove Prior operation: Remove the engine (refer to Engine - Remove (10.001)).

1. Remove the mounting cover from the transmission.

SS12N204

1

SS12N205

2

SS12N206

3

2. Slowly rotate the flywheel to remove the nuts used to secure the transmission clutch to the engine.

3. Loosen the transmission mounting to the engine.

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Transmission - Transmission/Rear drive

4. Use a jig (2) to hang the transmission from a lifting device of sufficient load capacity. Remove all bolts and put the transmission aside on a proper pedestal and secure against any overturning.

SS12N738

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4

Transmission - Transmission/Rear drive

Transmission/Rear drive - Install 1. Move the transmission into position behind the engine.

SS12N738

1

SS12N206

2

SS12N205

3

SS12N204

4

2. Mount the transmission to the engine.

3. Slowly rotate the flywheel to install the nuts used to secure the transmission clutch to the engine.

4. Install the mounting cover on the transmission.

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Transmission - Transmission/Rear drive

Transmission/Rear drive - Filling 1. Remove the dipstick and the pour 21.5 L (5.7 US gal) of CASE AKCELA ATF, ATF DEXRON II through the hole and to the FULL mark.

SS12E008

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1

Transmission - Transmission/Rear drive

Transmission/Rear drive - Troubleshooting Problem Low clutch pressure

Insufficient converter power

Possible Cause Low oil level Clutch control valve jammed in open position Charging pump malfunctions Broken, worn or torn shaft sealing rings

Correction Refill oil to required level.

Clean the control valve and the transmission slide valve.

Replace the pump.

Replace the clutch sealing rings or the piston sealing rings.

Discharge valve for clutch piston jammed Clean the discharge valve thoroughly. in open position.

Low oil level Refill oil to the required level.

Suction strainer clogged Defective charging pump Low engine speed

Overheating

Converter runs loud

Worn and torn oil sealing rings Worn charging pump Low oil level Worn charging pump Damaged bearings

Machine does not start to Low oil level move when controller is shifted to “ F” or “ R” Blown fuse Stuck or broken relay Failed gear selector(s)

Clean the suction strainer.

Replace the charging pump.

• Adjust the engine.

• Check the rpm controller.

Disassemble the unit and replace sealing rings..

Replace the pump.

Refill oil to the required level Replace the pump.

Unit must be removed to determine which bearing is defective.

Refill oil to the required level.

Check the fuses.

Check the relays.

• Check the fuse.

• Check the connectors for corrosion.

Failed steering changeover electronics

• Check for voltage and ground at the connectors.

• Check the connectors for corrosion.

Failed solenoid valves

• Check for voltage and ground at the connectors.

• Check the connectors for corrosion.

• Check for voltage and ground at the solenoid connectors.

• Check the resistance of the solenoid circuit.

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Index Transmission - 21 Transmission/Rear drive - 118 Mechanical transmission - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Transmission/Rear drive - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Transmission/Rear drive - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Transmission/Rear drive - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Transmission/Rear drive - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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

PRINTED IN U.S.A. © 2015 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

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

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

47703681 09/09/2015 EN

SERVICE MANUAL Front axle system PT240

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Contents Front axle system - 25

[25.400] Non-powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1

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Front axle system - 25 Non-powered front axle - 400

PT240

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Contents Front axle system - 25 Non-powered front axle - 400

FUNCTIONAL DATA Front axle Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Axle wheel hub Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE Front axle Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Axle wheel hub Replace – Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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Front axle system - Non-powered front axle

Front axle - Component identification

SS12N060

1

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Front axle system - Non-powered front axle

Position 1 2 3 4 7 8 9 10 11 12 13 14

Designation Front foot Connecting pipe Pin with flange Steering lever Pin Ring Ring Washer Washer Bush Screw Box

Position 16 17 18 19 25 27 30 34 37 38 39 40

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Designation Connecting pipe Connecting rod Lock ring Grease nipple Spring washer Spring washer Nut Bolt Cap Quick coupling Cover Steel wire

Front axle system - Non-powered front axle

Axle wheel hub - Component identification

SS12N059

1

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Front axle system - Non-powered front axle

Position 1 2 3 5 6 9 10 11 12 14 15 16 17

Designation Foot Bolt Axle Hub Ring Bearing Bearing Oil seal Oil seal Nut Grease nipple Nut Locking sheet

Position 19 22 23 24 30 31 32 34 35 36 37 39 40

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Designation Cylindrical pin Bolt Thrust ring Bush Box Box Box Spring washer Washer Washer Spring washer Bolt Bolt

Front axle system - Non-powered front axle

Axle wheel hub - Sectional view

SS13G129

Position 1 3 4 5

Designation Cylinder Cover Stop Scraper ring

1

Position 8 9 10 11

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Designation Guide band Guide band Thrust ring Sealing ring

Front axle system - Non-powered front axle

Front axle - Remove NOTE: For more details refer to Front axle - Component identification (25.400).

1. Route proper rigging in the machine's lifting lugs.

Lift the front of the machine slightly so that the front wheels do not touch the ground.

Put proper supports under the machine frame.

SS12E025

1

SS12E074

2

SS12E075

3

SS13A169

4

2. Remove the cover in the frame over the front wheels, and set it aside with a lifting device.

3. Remove the pipe for leveling including the connecting pipe.

4. Remove the steering joint.

5. Press out the ball joint.

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Front axle system - Non-powered front axle

6. Use a lifting device and a jig to suspend the axle.

7. Undo the nuts and bolts that secure the axle.

SS13A170

5

SS13A171

6

8. Lower the axle to the ground.

ATTENTION: Direct the cutout for the sprinkler hose ahead during axle reinstallation.

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Front axle system - Non-powered front axle

Front axle - Install NOTE: For more details refer to Front axle - Component identification (25.400).

1. Use a lifting device and a jig to suspend the axle.

2. Install the nuts and bolts that secure the axle.

SS13A170

1

SS13A169

2

SS12E075

3

SS12E074

4

3. Press in the ball joint.

4. Install the steering joint.

5. Install the pipe for leveling including the connecting pipe.

6. Install the cover in the frame over the front wheels.

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Front axle system - Non-powered front axle

Front axle - Alignment 1. Start by shifting the piston rod in to and then out of the cylinder at (A) = 94 mm (3.7 in).

NOTE: Adjust the geometry for front axle leveling. Fill the cylinder with hydraulic oil following geometry adjustment – refer to Steering cylinder - Filling (41.216).

SS13A056

1

SS13A057

2

SS13A058

3

SS13A059

4

2. Position a hand jack under both front foot (1) and shift in a jig (4).

3. Lift to adjust the extent of shifting out at (B) = 288.00 294.00 mm (11.34 - 11.57 in).

4. Position the ruler as shown in image 4.

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Front axle system - Non-powered front axle

5. Slacken the bolts (A) on both connecting rods and turn the connecting rods (17) slightly to adjust the hub position.

Adjust so that the hubs of both legs touch the ruler (parallel position).

When adjusted, tighten the connecting rod bolts.

SS13A060

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5

Front axle system - Non-powered front axle

Axle wheel hub - Replace – Seals Prior operation: Remove the front axle. Please see Front axle - Remove (25.400) for details.

NOTE: For more details, refer to Axle wheel hub - Sectional view (25.400) NOTE: The set of seals includes guide strips (located in the pipe). These do not require replacement unless the shaft surface has been damaged (scratches, scores, etc.) during operation and this has led to guide strip damage.

1. Remove the cover, and slide the shaft into the cylinder until the end moves out of the cylinder and the stop appears.

SS13A158

1

SS13A153

2

SS13A061

3

2. Remove the stop (4), and pull the shaft out of the cylinder.

1. Set the cylinder (1) to the vertical position and secure it.

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2. Remove the old scraper ring.

SS13A140

4

SS13A069

5

SS13A068

6

SS13A067

7

3. Remove the old spacer ring.

4. Remove the old cuff.

5. Remove the old sealing ring.

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Front axle system - Non-powered front axle

6. Remove the old O-ring.

SS13A065

8

SS13A062

9

7. Remove the old guide bands and insert the new guide bands (8), (9).

8. Turn the new guide bands towards each other so that the gaps dividing the planes are turned at an angle of about 90 °.

SS13A063

10

SS13A065

11

9. Insert the new O-ring.

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Front axle system - Non-powered front axle

10. Insert the new sealing ring with the blade facing down.

SS13A067

12

SS13A068

13

SS13A069

14

SS13A140

15

11. Install the new cuff.

12. Install the new spacer ring above the cuff.

NOTE: Do not force the spacer ring. Damage may occur to the spacer ring.

13. Insert the new scraper ring.

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Front axle system - Non-powered front axle

14. Use a magnet or adequate lifting device to hang the assembly.

15. Lubricate the sliding surfaces to protect the rings from damage.

SS13A141

16

SS13A142

17

SS13A144

18

SS13A145

19

16. Reposition in the jig.

17. Lubricate the cylinder liner gasket.

18. Lubricate the shaft surface.

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19. Fit the lifting lug into the shaft.

SS13A146

20

SS13A147

21

SS13A148

22

SS13A151

23

20. Hang on the lifting device, and slide the shaft into the cylinder. Turn the shaft slightly when installing.

NOTE: When installing, make sure that the scraper ring (5) does not get folded.

21. Turn the assembled unit over to the horizontal position.

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22. Insert the stop (4) into the shaft groove, and slide the shaft back in the cylinder.

SS13A153

24

SS13A154

25

SS13A155

26

SS13A156

27

23. Insert the thrust ring (10) onto the cover (3).

24. Fit the sealing ring (11) onto the cover.

25. Clean the sealing surface and threads.

26. Lubricate the thread.

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Front axle system - Non-powered front axle

27. Pour 3.0 L (3.2 US qt) of CASE AKCELA HY-TRAN® ULTRA™ HYDRAULIC TRANSMISSION OIL into the cavity between the stop and the cover.

28. Screw on and tighten the cover (3).

SS13A157

28

SS13A158

29

SS13A159

30

29. Install an air valve for pressure testing.

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Front axle system - Non-powered front axle

30.

WARNING Pressurized system!

Air pressure will quickly move the shaft out from the cylinder and up to the stop.

Failure to comply could result in death or serious injury.

W1131A

Connect an air hose with quick coupling, and fill to a pressure of 5 bar (72.5 psi).

NOTICE: Do not exceed the maximum pressure.

SS13A160

31

SS13A161

32

SS13A162

33

SS13A163

34

31. Spray soapy water around the assembly to check for leaks between the cylinder and shaft.

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32. If no leaks are found, secure by snapping the cover against the release.

SS13A164

35

SS13A076

36

SS13A152

37

SS13A077

38

33. Remove the air valve and install a lifting jig.

34. Use a lifting device to turn the assembly to the vertical position.

35. While slightly turning, slide the shaft into the cylinder.

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36. Turn the assembled unit over to the horizontal position.

SS13A335

39

SS13A165

40

37. Remove the lifting jig.

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Front axle system - Non-powered front axle

Axle wheel hub - Disassemble NOTE: For more details refer to Axle wheel hub - Component identification (25.400).

1. The hubs (5) can be removed without removing the axle from the machine. In order, remove the covers (30), (31), the tire, the filling pipe, the inlet (B), the support shaft (3), and the bracket (A).

SS12N747

1

SS13A172

2

SS13A173

3

SS13A110

4

2. Unlock and remove the washers and nuts one by one.

Pull down the hub using a crowbar.

NOTE: The ring (11) is secured with a pin (19) underneath the hub.

3. Drive the oil seals (11) and (12) out of the hub on both sides.

4. Drive out the inner rings of the bearings (9) and (10).

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Front axle system - Non-powered front axle

Axle wheel hub - Assemble NOTE: For more details refer to Axle wheel hub - Component identification (25.400).

1. Insert the outer ring of the bearing (9) into the hub (5).

NOTE: If the hubs require replacement, the wheel bolts must be welded to the hub.

Put the bolts in the hubs, preheat to 200 - 250 °C (392 482 °F) and weld the bolt heads alternately, using a fillet weld.

Electrode: EN 1600: E18 8 MN B 4 2 SFA/AWS A 5.4: E 307-15

SS13A125

1

SS13A126

2

SS13A111

3

SS13A127

4

2. Use an adequate tool to tap the outer ring (9) into the hub.

3. Insert the seal ring (11) into the hub (9).

4. Install the seal by using an adequate seal installer.

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Front axle system - Non-powered front axle

5. Turn the hub and tap the outer ring of the bearing (10), using adequate equipment.

SS13A174

5

SS13A175

6

SS13A176

7

SS13A177

8

6. Genitally press the oil seal, with blade outward, into the hub.

7. Install the grease nipple (15).

8. Preheat the inner ring of the bearing (9) to 100 °C (212 °F).

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Front axle system - Non-powered front axle

9. Suspend the shaft (3), and turn to the vertical position.

Insert the heated ring of the bearing (9).

SS13A178

9

10. Push the bearing (9) to the stop.

SS13A179

10

SS13A180

11

SS13A181

12

11. Lubricate the bearing and space between bearings with grease.

12. Fit the hub (5) onto the shaft (3).

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13. Insert the inner ring of the bearing (10), and lubricated with grease.

SS13A182

13

SS13A183

14

SS13A122

15

SS13A184

16

14. Tap the outer ring of the bearing (10) .

15. Insert the ring (6).

16. Install the nut (16), and torque to 498.0 - 502.0 N·m (367.3 - 370.3 lb ft).

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Front axle system - Non-powered front axle

17. Tap the ring (6) to seat the bearing (10), and torque again to 498.0 - 502.0 N·m (367.3 - 370.3 lb ft).

SS13A185

17

SS13A186

18

SS13A187

19

SS13A123

20

18. Insert both washers (17), and partially bend the lower washer into the nut cut-out.

19. Install the nut (16).

20. Torque the nut (16) to 498.0 - 502.0 N·m (367.3 370.3 lb ft).

21. Check that the nut’s upper surfaces is flush with the shaft end.

NOTE: Unless the washer is able to bend partially into the cut-out, tighten the nut more – never slacken.

22. Lock the washers.

23. Install the hub’s second side.

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Front axle system - Non-powered front axle

24. Turn through an angle of 90 ° and remove the bearing’s upper halves.

SS13A188

21

SS13A124

22

SS13A112

23

SS13A113

24

25. Tap the pin (19) into both halves of the removed bearing.

26. Install adequate lifting equipment (3).

27. Suspend on the lifting device and pull the piston rod to the stop.

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Front axle system - Non-powered front axle

28. Insert into the shaft.

SS13A114

25

SS13A115

26

SS13A116

27

SS13A117

28

29. Fit the ring (23) and bush (24) from both sides.

30. Mount it.

31. Center the hole for the pin in the ring (23) against the hole in the cylinder.

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Front axle system - Non-powered front axle

32. Install the upper halves of the bearing, secure the bolts with LOCTITE® 262™, and torque to 80 N·m (59 lb ft).

SS13A118

29

SS13A219

30

SS13A120

31

33. Tap the pin to the stop; and lock the ring (23) against rotation.

34. Install the cover (31) and insert the washer underneath the cover – take up the clearance between cover and shaft.

ATTENTION: Direct the cutout for the sprinkler hose ahead during axle reinstallation.

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Front axle system - Non-powered front axle

Axle wheel hub - End play CAUTION Avoid injury!

Keep hands and feet clear of the machine during raising and lowering operations.

Failure to comply could result in minor or moderate injury.

C0079A

1. Raise the front part of the machine slightly so the wheels do not touch the ground.

2. Secure the rear wheels with wheel chocks.

3. Support the front part of the frame with adequate lifting equipment.

SS12E025

1

SS12E026

2

SS12E027

3

4. Check the bearing play by grasping a wheel with both hands and wiggle the wheel in a rocking motion.

If there is no play in the bearing, the bearings do not need to be adjusted.

If there is bearing play, please proceed to step 5.

5. Remove the pipe hose (1).

6. Release the nuts (2).

7. Remove the disc inclusive tire (3).

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Front axle system - Non-powered front axle

8. Unlock the external washer (3).

9. Slowly tighten the internal groove nut (2) while at the same time striking the wheel hub (4).

10. Check that the bearings (1) are tightened.

There must be no play and the complete wheel must rotate with no resistance.

11. Reinstall the washer (3).

12. Tighten the groove nut (2) to 500 N·m (369 lb ft), and secure by bending the washer (3) slightly.

13. Reinstall the disc, including the tire, the inflating hose, and the wheel nuts.

Tighten the wheel nuts to 400 N·m (295 lb ft).

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SS12E028

4

Index Front axle system - 25 Non-powered front axle - 400 Axle wheel hub - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Axle wheel hub - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Axle wheel hub - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Axle wheel hub - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Axle wheel hub - Replace – Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Axle wheel hub - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Front axle - Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Front axle - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Front axle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Front axle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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

PRINTED IN U.S.A. © 2015 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

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

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

47703681 09/09/2015 EN

SERVICE MANUAL Rear axle system PT240

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Contents Rear axle system - 27

[27.100] Powered rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1 [27.124] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2

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Rear axle system - 27 Powered rear axle - 100

PT240

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Contents Rear axle system - 27 Powered rear axle - 100

FUNCTIONAL DATA Powered rear axle Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE Powered rear axle Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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Rear axle system - Powered rear axle

Powered rear axle - Component identification

SS12N066

1

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Rear axle system - Powered rear axle

Position 1 2 4 5 6 7 8 10 11 12 13 14 16 17 18 19 20 21 23 25 27 28 29

Designation Left-hand box Right-hand box Shaft Intermediate gear Gearwheel Gear pin Flange Brake assembly Brake drum Cover Bearing cover Bearing cover Spacer ring Cover Paper gasket Ring Shim Shim Spacer ring Plug Bearing Bearing Bearing

Position 31 32 33 34 35 37 38 39 42 43 44 45 46 47 49 50 51 52 55 56 58 59 62

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Designation Ring Ring Oil seal Nut Lock washer Lock ring Lock ring Lock ring Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Nut Nut Spring washer Spring washer Spring washer Washer Bleeder valve

Rear axle system - Powered rear axle

SS12N068

2

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Rear axle system - Powered rear axle

Position 1 2 3 4 5 6 7 9 10 11 12 13 14 16

Designation Rubber dust cup, left-hand Rubber dust cup, right-hand Flange Splined shaft Splined shaft Pinion Shim Bolt Fork Steel plate Lock ring Final drive Bearing Sealing ring

Position 17 18 19 20 21 22 23 25 26 28 29 30 31 33

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Designation Nut Cylinder Drain cock Reducing piece Joint Cap nut Washer Spring washer Spring washer Bolt Set screw Countersunk screw Bolt Nut

Rear axle system - Powered rear axle

Powered rear axle - Static description The assembly is mounted on the machine’s cruciform frame and consists of two column-type boxes coupled via an axle bridge and rubber dust cups.

Transmission torque is transmitted via a joint shaft to the final drive, including differential. The main function of the final drive is to secure distribution of power to two sides depending on loading of both outlets. Intake torque is transmitted via an OERLIKON SPRIOMATIC bevel gear via classic bevel differential to the half axles and then on to the gearings embedded in column-type boxes. Drive gear hubs with brake drums are mounted on the outlet shaft groove.

To facilitate removal and installation operations, the figure shows an overall exploded view of the rear axle drive along with specifying individual parts. This enables swift and easy orientation during any of their replacement. Due attention should be paid to retightening of all bolts and nuts. Observe the required tightening torques.

Specifications Type of rear axle transmission: Down transmission Max power transmitted Max input rpm Max input torque Mk Axle weight

Gears with rectilinear face toothing constantly engaged 78.0 kW (106.1 Hp) 2500 RPM 3800 N·m (2803 lb ft) 1320 kg (2910 lb)

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Rear axle system - Powered rear axle

Powered rear axle - Cleaning Cleaning parts Use a proper bath consisting of a liquid with soluble effects to ensure perfect cleaning of parts. Bearings need to be removed from the bath several times and turned slightly under pressure by tapered rollers and rollers.

Once they are perfectly clean, dry the bearings with dry compressed air. When drying, turn the bearings slowly by hand to speed up the drying process.

Inspecting individual parts Visually inspect all tapered rollers, rollers, cages (snap rings) and bearing rings for pitting, open or broken sections of materials and notches. Replace any damaged bearings. For tapered roller bearings, replacement of only the inner or outer rings is forbidden.

Once inspection is complete, dip the bearing in oil, take it out, and wrap it in paper to ensure it remains clean until reinstallation.

Crack detection agent should be used if possible. If this is not available, inspect the parts for dents, pitting, cracks, and overall wear and tear. Small notches can be eliminated by a suitable abrasive stick. In the event of significant damage (cracks, cementation layer broken through, etc.) such part must be replaced.

On shafts, check their runout (untrue running), straightness of grooves, and clearance in toothed grooves when the counterpiece is fitted (half axle – planetary gear, etc.).

Visual inspection includes any occurrence of notches or burrs on functional surfaces and holes for bearings.

In addition, thoroughly check for cracks and deformation. For the differential hub assembly and differential casing, check for basic deviations of geometric shapes (e.g. axial alignment, untrue running, etc.).

If any cracks, depth damage, or wear and tear found during inspection of the brake drum (scratches, etc.) cannot be eliminated by re-lathing the drum even to max. 402.5 mm (15.8 in), then the drum must be replaced.

1. Replacement is required if even very minor damage is detected.

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Rear axle system - Powered rear axle

Powered rear axle - Remove Prior operation: Remove the water tank.

NOTE: For more details, refer to Powered rear axle - Component identification (27.100).

1. Drain the fuel..

NOTICE: Collect the fuel in a suitable container.

SS12N209

1

SS12N210

2

SS12N211

3

2. Remove the reversing horn.

3. Mark and disconnect the fuel gauge connectors.

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Rear axle system - Powered rear axle

4. Remove the wiring clips along both sides.

SS12N212

4

SS12N213

5

SS12N214

6

5. Remove the fuel supply and overflow; plug the pipes.

6. Remove the thermal insulation curtains.

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7. Remove the thermal insulation covers.

SS12N215

7

SS12N216

8

SS12N217

9

8. Remove the reversing light lens; disconnect the wiring.

SS12N218

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10

Rear axle system - Powered rear axle

9. Install lifting lugs. Suspend from an adequate lifting device.

SS12N219

11

SS12N220

12

SS12N221

13

SS12N222

14

10. Remove the bolts used to secure the tank to the machine frame (both sides).

11.

WARNING Falling object hazard!

DO NOT go underneath a hanging load. Make sure the area is clear of all bystanders.

Failure to comply could result in death or serious injury.

W1129A

Put the fuel tank aside.

12. Remove scrapers and sprinklers.

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Rear axle system - Powered rear axle

13. Remove the steel sheets (E), (F).

14. Disconnect the lock wiring.

15.

SS12N223

15

SS12N224

16

SS12N724

17

SS12N725

18

WARNING Avoid injury!

Let the air out via the drain valve on the tank before removing the lock.

Failure to comply could result in death or serious injury.

W1130A

Remove the air supply used to control the differential lock.

16. Remove the floor covers (A), (B).

17. Remove the cover (C). Open the maintenance cover (D) and secure in the open position.

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Rear axle system - Powered rear axle

18. Remove the bolts securing the left seat.

NOTE: Remove the bolt inside the box (underneath the seat). This bolt secures the box to the machine frame.

SS12N723

19

SS12N355

20

SS12N208

21

SS12N225

22

19. Undo the seven bolts along the perimeter of the cab.

These bolts secure the cab to the machine frame.

20. Lift the cab.

21. Remove the seat from the cab.

22. Lift the machine. Support the rear section of the machine along both sides.

23. Turn off the parking brake.

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Rear axle system - Powered rear axle

24. Remove the air hose.

NOTE: Unless there is sufficient air pressure ( 5.3 bar (76.8 psi)) and the engine is operable to refill pressure, you must turn off the brakes. Please see step 25 if the engine in inoperable.

SS12N226

23

SS12N227

24

SS12N228

25

SS12N229

26

25. Install the brake release tool into the spring cylinder, and release the brake.

26. Support the joint shaft. Remove the bolts used to secure the shaft to the brake disk, and move the shaft aside.

27. Release the split pin, and eject the upper pin of the brake lever.

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Rear axle system - Powered rear axle

28. Disconnect the brake pull rods.

SS12N230

27

SS12N231

28

SS12N232

29

SS12E046

30

29. Remove the brake.

30. Remove the disk.

31. Remove the plate with the spring cylinder.

32. Loosen the wheel nuts but do not remove.

33. Route proper rigging in the machine's lifting lugs. Lift the rear of the machine slightly so that the rear wheels do not touch the ground. Support the machine frame in a suitable manner.

34. Remove the tires, brake hoses, and wheels.

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Rear axle system - Powered rear axle

35. Use proper rigging to suspend the rear axle on a lifting device.

36. Remove the bolts (50) and nuts (52).

SS12N782

31

SS12N773

32

SS12N739

33

37. Remove the drain plug for the final drive (13). Drain the oil into a suitable vessel.

38. Place the rear axle onto a jig, and position in a vertical position.

39. Secure the brake drums with two nuts (51).

40. Remove the plugs from the right-hand box (2) and left-hand box (1).

41. Drain the oil into a suitable container.

42. When the oil is drained, install all of the drain plugs, do not tighten.

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Rear axle system - Powered rear axle

Powered rear axle - Disassemble NOTE: For more details, refer to Powered rear axle - Component identification (27.100).

NOTE: If continued use of main parts (gears, pinions, grooved shaft, flange) is expected, then mark these items properly to ensure they are reinstalled to their original positions.

1. Place the axle in horizontal position.

2. Remove all bolts securing the left-hand and right-hand rubber dust caps (1) and (2) with the left-hand box and right-hand box.

3. Install two M12 extractor bolts into the M12 holes, and tighten them slowly to separate the axle bridge along with the rubber dust caps and half axles, including six pinions for the left-hand and right-hand boxes.

SS12N761

1

SS12N741

2

SS12N771

3

4. Use a lifting device and a jig (4) to relocate the removed final drive housing. Embed the drive housing in the horizontal position on a suitable pedestal with the flange facing down.

5. Remove the assembled half axles (4) from the axle center.

6. Remove the pinions (6) —including the bearing inner ring— from the half axles, using a puller.

7. Remove the washer (7) and safety ring (12).

8. Remove the bearing inner ring (14).

9. Remove the rubber dust cup right (2).

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Rear axle system - Powered rear axle

10. After removing both rubber dust cups from the final drive (13), replace the oil seals (B) and O-ring (A) before reinstallation.

SS12N069

4

SS12N067

5

SS12N784

6

SS12N743

7

11. After removing both rubber dust cups from the final drive with differential lock (13), replace the oil seals (B), (C) and O-ring (A).

12. Remove the two nuts (51) used to secure the brake drum (11).

13. Remove the brake drum from the flange bolts.

NOTE: If required, insert extractor bolts into the holes in the drum.

14. Release the lock washers (35).

15. Remove the nut (34) with a jig (5).

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Rear axle system - Powered rear axle

16. Remove the washers (35), remove the second nut (34), and take out the spacer ring.

SS12N783

8

SS12N785

9

17. Heat the flange to 320 °C (608 °F).

18. Use a suitable puller to remove the flange (8) from the shaft spline (4).

19. Remove the bolts (47), and remove the brake device (10).

SS12N786

10

SS12N789

11

20. Screw the M16 extractor bolts into the two M16 holes, and tighten them slowly to remove the cover (12).

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Rear axle system - Powered rear axle

21. Remove the oil seal (33) from this cover.

22. Remove the washers (20) and (21), the ring (19), and the O-ring (32).

23. Use a lifting device to turn the housing 180 ° (with the cover (13).

SS13A045

12

SS12N788

13

SS12N742

14

SS13A046

15

24. Remove the bolts (44) and (45).

25. Screw the two M16 extractor bolts into the M16 holes and tighten them slowly to remove the cover (13).

26. Install lifting lugs into the M16 holes, and use a suitable lifting device to place the assembly on a workbench.

27. When replacing the bearing (29), use a bronze bar to press or tap the bearing's external ring out of the cover (13).

28. Screw a lifting lug onto the shaft (4).

29. Use a lifting device to remove the assembly from the housing.

30. Remove the bolts (46).

31. Use a press to remove the gear wheels (6) and bearing inner rings (29).

32. If you replace the second bearing (29), use a bronze bar to tap the external ring out of the housing hub.

33. Remove the cover (17) with gasket (18).

34. Remove the safety rings (39).

35. Tap out the pins (7) using a bronze bar.

36. Remove the O-rings (31).

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Rear axle system - Powered rear axle

37. Remove the intermediate gears (5) from the housing.

SS12N744

16

SS12N745

17

SS13A046

18

SS12N774

19

38. Remove the second intermediate gear (5).

39. Remove the complete bearing (28), including safety rings (37) and spacer (23).

40. Remove the bolts (43).

41. Screw the M8 extractor bolts into the M8 holes and tighten them slowly to remove the cover (14).

42. Remove the bearing under the cover.

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Rear axle system - Powered rear axle

Powered rear axle - Assemble NOTE: For more details refer to Powered rear axle - Component identification (27.100).

Installing the drive casing 1. Clean the casings (1), (2).

SS12N790

1

SS13A046

2

SS12N791

3

2. Fit the safety rings (37) and bearing (28) in the holes of the intermediate gears (5).

3. Turn the gear around and push the ring (23) and the second bearing (28) into the hole from the other side.

4. Turn the casings 90 ° with the large hole facing down.

5. Tap the outer ring of the bearing (29) into the large hub.

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Rear axle system - Powered rear axle

6. Tap the oil seal (33) into the cover (12).

7. Apply LOCTITE® 518™ to the contact surfaces of the cover (12) and the hub.

8. Fit the cover (12) onto the casing hub.

SS12N793

4

SS12N792

5

SS12N790

6

SS12N744

7

9. Apply LOCTITE® 565™ PST to the bolt threads.

10. Fit the brake device (10) onto the casing hub, and secure it with the bolts (47).

11. Turn the casing 90 °.

12. Slide the two complete intermediate gears (5) into the casing – one through the casing’s rectangular hose and the other through the hole designed for the cover (13).

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Rear axle system - Powered rear axle

13. Turn the casing 90 ° with the large hole facing down.

SS12N745

8

SS12N795

9

14. Center the wheel bearing holes against the casing holes.

15. Fit the O-rings (31) and safety ring (38) onto the pins of the inserted gears (7).

16. Insert the pin (7).

SS12N794

10

SS12N746

11

17. Heat the gear (6) to 150 - 180 °C (302 - 356 °F).

18. Fit the gear onto the grooved shaft (4).

19. When cooled, bolt the unit together with the bolts (46).

Torque to specification. Torque specification can be found on. Torque ().

20. Heat the inner rings of the bearing (29) to 100 °C (212 °F), and fit them onto the shaft (4) from both sides.

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Rear axle system - Powered rear axle

21. Screw the lifting lug onto the shaft (4), and position the assembly unit into the outer ring of the bearing (29) in the cover (12).

SS12N742

12

SS12N796

13

SS12N797

14

SS12N798

15

22. Apply LOCTITE® 518™ to the contact surface of the cover (13) and the casing hole.

23. Screw lifting lugs with M12 thread into the extractor holes in the cover (13) and the position in the casing holes —the position of the recess (A) as indicated in image 13.

24. Seal the bolting (44), (45) with LOCTITE® 518™.

25. Tap the outer ring of the second bearing (29) into the cover (13).

26. In order to install the cover (13), the bearing preload (29) must be set by inserting the shims (20), (21). The bearing preload should be 0.400 - 0.600 mm (0.016 0.024 in).

Determining preload size: 27. Measure (X) the size of the recess on the cover (12) as illustrated in image 15.

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Rear axle system - Powered rear axle

28. Measure (Y) distance between the outer ring of the bearing (29) and the face of the cover (13) as illustrated in image 16.

29. Calculate the bearing preload size “P”: P=Y–X Determine the thickness of the “Z” shims: Z = P + 0.4

SS12N799

16

SS12N800

17

SS12N801

18

SS13A011

19

30. Apply LOCTITE® 518™ to the contact surfaces of both covers (12), (13). Use the preload calculation to prepare, and insert shims (20), (21) into the holes of the cover (13).

31. Put cover (12) to cover (13). Fit the brake device (10) onto the cover (12) and screw on the bolts (47). Seal the threads with LOCTITE® 565™ PST.

32. Fit the O-ring (32) and chrome ring (19) onto the shaft.

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Rear axle system - Powered rear axle

33. Insert the bolts (49) into the hubs.

34. Install the nuts (51), and tighten the bolts together with the jig towards the hub flange.

35. Preheat the hub to 200 - 250 °C (392 - 482 °F) in an electric furnace.

36. Weld the bold heads on both sides.

Identification of electrodes under the following standards: DIN 8556: E 18 8 Mn B 20+ AWS A/SFA 5.4 – 92: E 307 – 15 DEN 1600 (European Standard): E 18 8 Mn B42 SS13A012

20

SS13A013

21

SS13A014

22

SS13A015

23

37. Heat the flange (8) to 200 - 250 °C (392 - 482 °F), and slide it into the spline of the shaft.

38. Slide the spacer ring (16) onto the shaft.

39. Install the nut (34). Torque the nut (34) to 450 500 N·m (332 - 369 lb ft).

40. Secure with a washer (35).

41. Install the second washer (34), and secure with the reed washer (35).

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Rear axle system - Powered rear axle

42. Fit the brake drum (11) onto the flange bolts, and secure with two nuts (51).

SS13A016

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24

Rear axle system - Powered rear axle

Powered rear axle - Install NOTE: For more details, refer to Powered rear axle - Component identification (27.100).

1. Use a lifting device to suspend the rear axle. Position its plates near the machined surfaces of the frame and bolt them to the frame using bolts (50), washers (59), and nuts (52).

SS13A019

1

SS12N232

2

SS12N231

3

2. Install the tires, brake hoses, and wheels.

3. Install the plate with the spring cylinder.

4. Remove the disk.

5. Remove the brake.

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Rear axle system - Powered rear axle

6. Connect the brake pull rods.

SS12N230

4

SS12N229

5

SS12N228

6

SS12N227

7

7. Install the upper pin of the brake lever.

8. Install the bolts used to secure the shaft to the brake disk. Torque to 75 N·m (55.3 lb ft).

NOTE: Use new self-locking nuts during reinstallation.

9. Remove the brake release tool.

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Rear axle system - Powered rear axle

10. Install the air hose.

SS12N226

8

SS12N208

9

11. Verify parking brake is on or turn the parking brake.

12. Install the seat.

13. Lower the cab.

14. Undo the seven bolts along the perimeter of the cab.

These bolts secure the cab to the machine frame.

SS12N355

10

SS12N355

11

15. Install the seven bolts along the perimeter of the cab.

These bolts secure the cab to the machine frame.

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Rear axle system - Powered rear axle

16. Install the bolts securing the left seat.

SS12N723

12

SS12N725

13

SS12N724

14

SS12N224

15

17. Install the cover (C).

18. Install the floor covers (A), (B).

19. Install the air supply used to control the differential lock.

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Rear axle system - Powered rear axle

20. Install the steel sheets (E), (F).

21. Connect the lock wiring.

SS12N223

16

SS12N222

17

SS12N221

18

SS12N220

19

22. Install scrapers and sprinklers.

23.

WARNING Falling object hazard!

DO NOT go underneath a hanging load. Make sure the area is clear of all bystanders.

Failure to comply could result in death or serious injury.

W1129A

Lower the fuel tank into position.

24. Install the bolts used to secure the tank to the machine frame (both sides).

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25. Install the reversing light lens; connect the wiring.

SS12N218

20

SS12N215

21

SS12N216

22

SS12N217

23

26. Install the thermal insulation covers.

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27. Install the thermal insulation curtains.

SS12N214

24

SS12N213

25

SS12N212

26

SS12N211

27

28. Install the fuel supply and overflow.

29. Install the wiring clips along both sides.

30. Connect the fuel gauge connectors.

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31. Install the reversing horn.

SS12N210

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28

Rear axle system - Powered rear axle

Powered rear axle - Filling 1. Clean and remove the plug on the rear side of the housing.

2. Check whether the oil level aligns with the inspection hole or flows out slightly.

3. If the oil level is not aligned with the inspection hole, fill the housing with CASE AKCELA GEAR 135 H EP 85W-140.

SS12E044

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1

Index Rear axle system - 27 Powered rear axle - 100 Powered rear axle - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Powered rear axle - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Powered rear axle - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Powered rear axle - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Powered rear axle - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Powered rear axle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Powered rear axle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Powered rear axle - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Contents Rear axle system - 27 Final drive hub, steering knuckles, and shafts - 124

SERVICE Final drive hub, steering knuckles, and shafts Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Final drive hub, steering knuckles, and shafts - Drain fluid 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 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

1. Drain the sprinkling tank.

2. Remove the sprinkling tank.

SS12E058

1

SS12E059

2

3. Remove the filler plug (1), then the drain plug (2), and drain the oil into a suitable container.

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Final drive hub, steering knuckles, and shafts - Remove DANGER Heavy objects!

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

Failure to comply will result in death or serious injury.

D0076A

NOTE: For more details, refer to Powered rear axle - Component identification (27.100).

1. Hang the final drive onto a suspension device, using a jig (4).

SS12N741

1

SS12N770

2

SS12N761

3

2. Remove the cover (14).

3. Use an adequate lifting device to suspend the final drive (13) and drive castings.

4. Unbolt the axle shafts (1), (2) from the drive castings.

5. Carefully remove the drive castings from the axle shafts.

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6. Remove the assembled half axles (5).

NOTE: The same is valid for the half axle (4).

SS12N766

4

SS12N763

5

SS12N764

6

7. Unbolt the dust cups (1), (2).

8. Remove the pinion (6) from the spline of the axle shaft.

9. Remove the safety ring (12).

10. Remove the four shims (7).

11. Remove the bearing (14).

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Final drive hub, steering knuckles, and shafts - Install DANGER Heavy objects!

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

Failure to comply will result in death or serious injury.

D0076A

NOTE: For more details, refer to Powered rear axle - Component identification (27.100).

1. Check the O-ring (A) and oil seal (B), (C) for damage.

SS12N067

1

SS12N762

2

SS12N763

3

2. Fit a new O-ring onto the flange of the rubber dust cup. .

3. Combine the rubber dust cups. Tap the oil seal into the hole in the rubber dust cup.

NOTE: The same is valid for the half axle (4).

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4. Heat the inner ring of the bearing (14) to 100 °C (212 °F).

NOTE: The same is valid for the half axle (5).

5. Insert the four shims (7) (for adjusting axial clearance), and install the safety ring (12).

SS12N764

4

SS12N765

5

SS12N741

6

SS12N766

7

6. Put the pinions (6) onto the spline of the half axles (4), and heat to 100 °C (212 °F). Secure with the lock ring (12).

7. Push the inner ring of the bearing (27) by means of a jig (7).

NOTE: The same is valid for the half axle (5).

8. Hang the final drive onto a suspension device, using a jig (4).

9. Slide the assembled half axles (5), including the outer rings of bearings (14), into the rubber dust cups (1).

NOTE: The same is valid for the half axle (4).

10. Check the differential lock operation.

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11. Position both casings besides each other. Lay them on a flat, paved, work surface to install the final drive.

12. Use a lifting device to suspend the final drive (13), and lift it between the drive casings.

13. Align the axis of the final drive rubber dust cup with the holes for the casings (1) (2).

14. Shift the final drive a bit closer to the casing and connect with the bolt.

15. Support the final drive (13) with suitable lifting equipment.

16. Use a lifting device to suspend the second casing.

SS12N761

8

SS12N767

9

17. Align the axes of the casings with the final drive, and connect with the bolts.

NOTICE: When fitting the final drive towards the casings (1), (2), turn the teeth pinions (6) slightly toward the gaps of the intermediate gear (5).

18. Press the outer rings of the bearings (27) in the covers (14).

19. Apply LOCTITE® 518™ to the contact surfaces of the covers (14).

20. Press the cover (14) gently into the hole of the casing, and attach the cover using the bolts.

SS12N770

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Rear axle system - Final drive hub, steering knuckles, and shafts

21. Install the flange (3) with bolts (28) to the final drive (13).

SS12N768

11

SS12N769

12

SS12N753

13

SS12N772

14

22. Insert the bolts (9), and secure them with nut (33).

23. Fasten a jig (3) to the bottom part of the casings. Use a lifting device to position the entire rear section of the axle into the vertical position.

24. Apply LOCTITE® 518™ to the rectangular hole of the casings (1) and (2) and the cover (17).

25. Position the gasket (18) along the perimeter (18), and bolt the cover.

26. Fill the casings (1) (2) with 5.2 L (1.4 US gal) of CASE AKCELA GEAR 135 H EP 85W-140.

27. Install the bleeding closures.

28. Fill the final drive (13) with 6.1 L (1.6 US gal) of TUTELA HYPOIDE EP GEAR LUBE SAE 80W-90.

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Final drive hub, steering knuckles, and shafts - Filling 1. Clean and unscrew the final drive inspection plug.

2. Check that the oil level is up to the inspection hole.

3. If the oil is not up to the inspection hole, fill with CASE AKCELA GEAR 135 H EP 80W-90.

4. Tighten the plug to 80 - 90 N·m (59 - 66.4 lb ft).

SS13G112

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1

Index Rear axle system - 27 Final drive hub, steering knuckles, and shafts - 124 Final drive hub, steering knuckles, and shafts - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Final drive hub, steering knuckles, and shafts - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Final drive hub, steering knuckles, and shafts - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Final drive hub, steering knuckles, and shafts - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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

PRINTED IN U.S.A. © 2015 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

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

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

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SERVICE MANUAL Brakes and controls PT240

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Contents Brakes and controls - 33

[33.300] Pneumatic service brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1 [33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2

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Brakes and controls - 33 Pneumatic service brakes - 300

PT240

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Contents Brakes and controls - 33 Pneumatic service brakes - 300

TECHNICAL DATA Pneumatic service brakes General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Compressor General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Pneumatic service brakes Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Pneumatic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Pneumatic service brakes Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Compressor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Air brake cylinder Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Brake components Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Shoe - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Drum - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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Pneumatic service brakes - General specification

SS12N750

1

Spring cylinder Component Spring cylinder

Pressure 8 bar (116 psi)

SS12N755

2

Diaphragm booster Component Diaphragm booster

Pressure 8 bar (116 psi)

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Compressor - General specification

SS12N728

1

Test ports Test port Steering system (1) Compressor system (2)

Pressure 140 bar (2030 psi) 210 bar (3045 psi)

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Pneumatic service brakes - Static description Description The service brake is controlled via a pedal in the operator area. It is defined as hydropneumatic circuit with integrated compressor, air dryer, pedal brake cylinder, air-liquid boosters, liquid tanks, pipes and brake device inside the rear wheels.

Compressed air under 8 bar (116 psi) pressure is supplied from an air tank via pipes to two pedal brake cylinders.

When one of the two pedal brake cylinders is depressed, compressed air flows from an air tank under 8 bar pressure through air channels of the pedal brake cylinder and via pipes down to a two-way valve (9) and then on to an air-liquid booster (7).

Inside the boosters, the air pressure is converted to brake fluid pressure. This pressure is then transferred by means of brake fluid via brake pipes to the brake cylinders that control the brake shoes on the rear wheels. When braked off, the brake fluid returns under pressure back to the air-liquid booster. Air from an air cylinder escapes via the pipes back to the pedal brake cylinder and to the atmosphere via the center of discharge valve.

BRAKE CIRCUIT Air operating pressure Brake drum diameter

8 bar (116 psi) 400 mm (15.7 in) H11

PEDAL BRAKE CYLINDER AIR-LIQUID BOOSTER Function: It consists of boosting air section and main hydraulic brake cylinder. The boosting air section is controlled by the main brake master cylinder for the air circuit. With the brake valve pedal depressed, the compressed air will break into air cylinder space and press the piston, which induces pressure in the main brake cylinder.

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Pneumatic service brakes - Pneumatic schema Position 1 2 3 4 5 6 7 8 9 10

Designation Air dryer Air tank 35 l (9.25 US gal) Pressure switch 5.2 bar (75 psi) Brake pedal Two-way valve Brake pedal Switch 450 - 550 kPa (65 - 80 psi) Diaphragm-type booster Electric valve Pneumatic distributor

Position 11 12 13 14 15 16 17 18 19

Designation Air gun Non-return valve Control valve Control valve Clogged filter switch 6 bar (87 psi) Compressor Four-way valve Electric valve Hand operated valve

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Schematic

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RAIL14COM0340JA

1

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Pneumatic service brakes - Adjust Adjusting brakes on both casings: 1.

Turn the brake drum slightly with the adjusting hole facing down towards the adjusting wheel (B).

2.

Turn the adjusting wheel (B) until the brake shoes lean against the brake drum (brake drum unable to rotate).

3.

Turn the adjusting wheel back just enough to release the brake shoes – the brake drum is now able to rotate, with no audible sounds of the drum rubbing the shoes.

SS13A017

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1

Brakes and controls - Pneumatic service brakes

Compressor - Test Check the following when the compressor power is insufficient: • Narrowed pressure line (carbon deposits) • System integrity (leaks) • If no defect is found, remove the cylinder head and test the suction plate and pressure plate along with the sealing.

• If the amount of carbon is high, check temperature conditions and compressor oil consumption • When replacing the compressor, check the discharge line to ensure it has not been fouled with carbon. If the line if fouled, replace it (and the pressure controller and air dryer also if necessary).

With the engine heated to operating temperature, follow the these instructions to check the oil consumption of the compressor: 1. Disconnect the suction line.

SS12N259

1

SS12N260

2

2. Disconnect the discharge line.

3. Let the engine run for about 2 min at half of the maximum RPM. 4. Position white paper on a fixed base in front of the compressor outlet —against air flow— for 5 min at an engine speed of about 1500 RPM. 5. The compressor will leave a light oil mist on the paper when the oil consumption is low.

If oil consumption is high, a focused black field will appear on the paper. A black field indicates a high level of wear inside the compressor.

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Compressor - Remove 1. Detach the discharge line.

SS12N253

1

SS12N254

2

SS12N255

3

SS12N258

4

2. Remove the lines.

3. Remove the pump.

4. Bleed water from the cooling system.

5. Remove the lubrication line.

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6. Remove the suction line.

SS12N259

5

SS12N260

6

SS12N261

7

7. Remove the discharge line.

8. Remove the compressor.

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Compressor - Install 1. Place the compressor in position, and shift the compressor in the oval-shaped holes of the bracket clutch to adjust the clearance of the segments..

2. Tighten in position after adjusting.

SS12N261

1

SS12N265

2

SS12N263

3

SS12N260

4

3. Check the condition of the sealing ring. Replace if necessary.

4. Install the discharge line.

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5. Install the suction line.

SS12N259

5

SS12N258

6

SS12N255

7

SS12N254

8

6. Install the lubrication line.

7. Install the pump.

8. Remove the lines.

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9. Attach the discharge line.

SS12N253

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Brakes and controls - Pneumatic service brakes

Air brake cylinder - Remove Removing the pedal brake cylinder 1. Pull the chain of the air tank drain valve to let compressed air out of the machine's air circuit.

SS12D625

1

SS12N207

2

SS12N374

3

SS13A023

4

2. Remove three floor covers at the operator area.

3. Lift the floor cover with pedals. Unscrew the connecting pipes from the brake master cylinder outlets on both sides.

4. Unscrew the four bolts and remove the brake master cylinder.

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Air brake cylinder - Remove 1. Blow off air via the blow-off valve on the air tank.

SS12D625

1

SS12N207

2

SS12N723

3

SS12N355

4

2. Remove the bolts and take out the floor cover. Lift off the automatic-transmission maintenance cover.

3. Remove the bolts securing the left seat.

NOTE: Remove the bolt inside the box (underneath the seat). This bolt secures the box to the machine frame.

4. Undo the seven bolts along the perimeter of the cab.

These bolts secure the cab to the machine frame.

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5. Lift the cab so that the seat can be moved.

SS12N208

5

SS12N359

6

SS12N246

7

SS12N247

8

6. Take the seat out of the cab.

7. Remove the booster bolts.

8. Remove the booster bracket.

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9. Remove the booster from the brake cylinder.

SS12N248

9

10. Take the booster out.

SS12N249

10

SS12N250

11

11. Release the hose (A) and drain brake fluid from the tank (catch any fluid). Remove the brake pipe (B) and the pressure sensor (C).

NOTE: Bleed the brake system after brake cylinder replacement (refer to Brake components - Bleed (33.300)).

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Brakes and controls - Pneumatic service brakes

Brake components - Remove Removing the brake shoe 1. If brake lining thickness is less than 2 mm (0.08 in), the lining must be replaced.

Remove the wheel (refer to Powered rear axle - Remove (27.100)).

Remove the pipes leading to the wheel brake cylinders. If required, replace the wheel brake cylinders as a whole. Catch any leaking brake fluid in a catch vessel.

Take the brake drum off the flange bolts. If required, use extractor bolts behind by the holes in the drum.

SS13A018

1

SS12N787

2

2. Detach the springs (A) and take out the shoes (B).

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Brake components - Bleed Both drums can be bled simultaneously.

Before starting the engine, make sure the travel controller is in the N position and the parking brake is applied to brake the machine.

NOTE: Check the brake shoe clearance once bleeding is complete. Rotate the brake drum manually. Adjust the shoes if necessary. Please see Brake components Shoe - Adjust (33.300) for details.

SS12E078

1

SS12N751

2

SS12N752

3

1. Pour brake fluid in the equalizer reservoir of the brake circuit, and keep it above the MIN level during the course of bleeding.

2. Slacken the vent plug (A) on the booster.

When the booster is filled up with fluid, close the vent plug.

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Brakes and controls - Pneumatic service brakes

3. Loosen the vent plug on the brake cylinder and slip the hose over its head.

4. Insert the other end of the hose into a transparent container that is filled with brake fluid.

NOTE: Verify that the hose end is submerged below the fluid level.

5. Start the engine. With the engine running, pressurize the brake system to the maximum value of 8 bar (116 psi).

6. Shut off the engine.

7. Simultaneously, depress the brake pedal repeatedly and replenish the equalizer reservoir with brake fluid.

8. When bubbles stop coming out of the submerged hose, tighten the vent plug and take off the hose.

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SS12E077

4

Brakes and controls - Pneumatic service brakes

Brake components Shoe - Adjust NOTICE: Adjust only cold brakes. Replace shoes all at once to maintain uniform braking. Always replace a defective adjusting device with the new one. Use only genuine brake shoes when replacing. No guarantee is granted when using non-genuine shoes or other non-genuine spare parts.

The brake has been equipped with a central adjusting device for both brake shoes. The lower floating suspension (A) serves as an adjusting device. Use the adjusting wheel (B) to mechanically adjust the clearance between the shoe and the drum.

NOTE: The drum has been removed for picture clarity. The drum does not need to be removed for this procedure.

SS13A024

1

SS12N227

2

SS13A017

3

1. Remove the wheel, but leave the brake drums fitted.

2. When there is a lack of air pressure in the brake circuit, release the brake shoes from the brake drum, using a tool (1), (2) to release the pneumatic brake.

3. Turn the brake drum manually with the adjusting hole facing down towards the adjusting wheel (B).

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Brakes and controls - Pneumatic service brakes

4. Rotate the adjusting wheel (B) until the brake shoes lean against the brake drum (brake drum unable to rotate).

NOTE: The drum has been removed for picture clarity. The drum does not need to be removed for this procedure.

5. Turn the adjusting wheel back just enough to release the brake shoes. The brake drum is now able to rotate with no audible sounds of the drum rubbing the shoes.

SS13A024

6. Reinstall the wheels, and tighten the wheel nuts to 400 N·m (295 lb ft).

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4

Brakes and controls - Pneumatic service brakes

Brake components Drum - Measure Re-machining the brake drums Re-machine brake drums when the friction surface of the drum has deep grooves.

Do not mount brake drums of different friction surface diameter onto individual parts of the brake device.

The diameter of the drum's brake surface machining must not exceed the maximum permissible diameter.

Original diameter 400 mm (15.7 in) H11

Max. diameter of machining 402.5 mm (15.8 in)

Axis alignment of friction surfaces against drum axis: ± 0.1 mm (0.004 in).

NOTICE: Make sure all drums are machined to the identical dimension.

Brake shoes with a thicker lining must be used for the machined drums.

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Index Brakes and controls - 33 Pneumatic service brakes - 300 Air brake cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Air brake cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Brake components - Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Brake components - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Brake components Drum - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Brake components Shoe - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Compressor - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Compressor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Compressor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Compressor - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Pneumatic service brakes - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Pneumatic service brakes - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Pneumatic service brakes - Pneumatic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Pneumatic service brakes - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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

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

FUNCTIONAL DATA Parking brake or parking lock Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Parking brake discs Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Parking brake caliper Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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Parking brake or parking lock - Component identification

SS12N727

1

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Brakes and controls - Parking brake or parking lock

Position 1 2 6 7 8 9 10 12 13 14 15 16 18 19

Designation Plate Lever Disc Pull rod Pin Cover Bolt Shim Shim Pin Pin Washer Washer Spring cylinder

Position 20 21 22 23 24 25 27 28 29 30 31 32 33

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Designation Yoke Bush O-ring Bolt Bolt Bolt Washer Washer Washer Split pin Grease nipple Washer Split pin

Brakes and controls - Parking brake or parking lock

Parking brake or parking lock - Static description It is used as a parking brake or emergency brake depending on the method of application.

The machine is braked automatically when it is stopped and when the engine is shut off. The parking brake is deactivated when the engine is started and the air circuit (air tank) is pressurized to 5.3 bar (76.8 psi). This is signaled by the indicator light being OFF. Use the switch on the instrument board to brake the machine while it is stationary with the engine running. At that time, a solenoid valve will open, air will escape from the spring cylinder and pressure against the spring will decrease.

The spring will then return to its home position. Use the lever mechanism gear to tighten the brake disc shoes – the machine is now braked.

Press the switch on instrument board to use the brake as an emergency brake during machine operation if the machine is unable to stop via the service brake. When this is done, the machine will stop and the engine will stall.

NOTICE: If the spring cylinder is damaged, always replace the damaged cylinder with a new one. Never try to disassemble the old one since the compressed state of the spring could cause injury.

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Brakes and controls - Parking brake or parking lock

Parking brake discs - Remove Prior operation: Remove the caliper. Please see Parking brake caliper - Remove (33.110).

NOTE: For more details, refer to Parking brake or parking lock - Component identification (33.110).

1. Support the joint shaft.

2. Remove the bolts connecting the shaft to the transmission.

SS12N376

1

SS12N228

2

3. Remove the bolts connecting the shaft to the brake disk.

4. Remove the brake disk.

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Parking brake discs - Install Prior operation: Remove the caliper. Please see Parking brake caliper - Remove (33.110).

NOTE: For more details, refer to Parking brake or parking lock - Component identification (33.110).

1. Install the brake disk.

2. Install the shaft.

3. Tighten the nuts to 75 N·m (55.3 lb ft).

NOTE: Use new self-locking nuts during reinstallation.

SS12N228

1

SS12N376

2

4. Connect the shaft to the transmission.

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Brakes and controls - Parking brake or parking lock

Parking brake caliper - Remove NOTE: For more details, refer to Parking brake or parking lock - Component identification (33.110).

1. Remove the floor covers (A), (B).

SS12N724

1

SS12N725

2

SS12N723

3

SS12N355

4

2. Remove the cover (C).

3. Open the maintenance cover (D), and secure in the open position.

4. Remove the bolts securing the left seat.

5. Undo the bolts along the perimeter of the cab.

NOTE: These bolts secure the cab to the machine frame.

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6. Lift the cab and secure in place using adequate lifting equipment.

SS12N208

5

SS12N359

6

SS12N225

7

SS12N226

8

7. Remove the left-hand seat to access the joint shaft.

8. Lift the machine. Support the rear part of the machine on both sides, using adequate lifting equipment.

9. Remove the air hose.

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Brakes and controls - Parking brake or parking lock

10. Use a tool (1), (2) to relieve pressure in the spring cylinder.

SS12N227

9

11. Release the split pin, and remove the upper pin from the brake lever.

SS12N229

10

SS12N230

11

SS12N233

12

12. Disconnect the pull rods.

13. Remove the brake.

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14. Remove the brake caliper and, If necessary, replace the brake pads.

SS12N234

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13

Brakes and controls - Parking brake or parking lock

Parking brake caliper - Install NOTE: For more details, refer to Parking brake or parking lock - Component identification (33.110).

1. If necessary, replace the brake pads at this time.

SS12N234

1

SS12N233

2

SS12N230

3

SS12N229

4

2. Place the caliper in position, and install. Torque the bolts to specification. Please see Torque () for specification.

3. Connect the pull rods.

4. Install the upper pin, and install the split pin.

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Brakes and controls - Parking brake or parking lock

5. Remove the tool (1), (2) that relieves pressure in the spring cylinder.

SS12N227

5

SS12N226

6

SS12N359

7

SS12N208

8

6. Install the air hose.

7. Install the left-hand seat.

8. Carefully lower the cab into position.

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Brakes and controls - Parking brake or parking lock

9. Install the bolts along the perimeter of the cab. Torque the bolts to specification. Please see Torque () for specification.

NOTE: These bolts secure the cab to the machine frame.

SS12N355

9

10. Install the bolts that secure the left seat.

SS12N723

10

SS12N725

11

SS12N724

12

11. Close the maintenance cover (D).

12. Install the cover (C).

13. Install the floor covers (A), (B).

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Index Brakes and controls - 33 Parking brake or parking lock - 110 Parking brake caliper - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Parking brake caliper - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Parking brake discs - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Parking brake discs - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Parking brake or parking lock - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Parking brake or parking lock - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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

PRINTED IN U.S.A. © 2015 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

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

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

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SERVICE MANUAL Hydraulic systems PT240

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Contents Hydraulic systems - 35

[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2

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Hydraulic systems - 35 Hydraulic systems - 000

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Contents Hydraulic systems - 35 Hydraulic systems - 000

FUNCTIONAL DATA Hydraulic systems Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic schema NOTE: All numerical values on the schematics are metric.

Schematic guide Line color Blue Green Position 1 2 3 4 5

Description Return to tank Charge pressure Designation Power steering valve Power steering valve Edge cutter block Compressor Non-return valve

Position 6 7 8 9 10

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Designation Filter + element Safety valve Engine Priority valve Logic valve

Hydraulic systems - Hydraulic systems

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Hydraulic systems - Hydraulic systems

RAPH14COM0516JA

1

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Hydraulic systems - Hydraulic systems

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Index Hydraulic systems - 35 Hydraulic systems - 000 Hydraulic systems - Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

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

SERVICE Oil reservoir Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Change fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Oil filters Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Accumulator Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Hydraulic systems - Reservoir, cooler, and filters

Oil reservoir - Remove 1. Drain the hydraulic oil.

SS12N073

1

SS12N251

2

SS12N252

3

2. Remove the cover.

3. Remove the hydraulic pipes.

Disconnect the wiring.

Remove the hydraulic tank clamping.

Take out the hydraulic tank.

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Oil reservoir - Change fluid 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 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

1. Open the cover.

2. Drain approximately 22 L (5.81 US gal) of oil into a suitable container.

3. When drained, close the valve.

SS12E063

1

SS12E064

2

SS12E072

3

4. Remove the cover.

5. Remove the fill plug.

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6. Fill the reservoir with hydraulic oil to the maximum level.

SS12E071

4

SS12E072

5

7. Reinstall the fill plug.

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Hydraulic systems - Reservoir, cooler, and filters

Oil filters - Replace 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 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

1. Open the cover.

2. With a suitable container of adequate capacity, drain the oil via the valve (Approximate drain volume: 22 L (5.81 US gal)).

3. When drained, close the valve.

SS12E063

1

SS12E064

2

SS12E065

3

4. Remove the cover.

5. Disconnect the clogged filter sensor (1).

6. Remove the filter cover (2).

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Hydraulic systems - Reservoir, cooler, and filters

7. Replace the filter element.

SS12E066

4

SS12E067

5

SS12E068

6

SS12E067

7

8. Disconnect the oil level sensor (3).

9. Remove the lines (4), (5) and cover (6).

10. Clean the tank interior.

11. Remove the suction strainer.

12. Clean the strainer with compressed air.

13. Check the condition of the suction strainer.

If the filtration part is damaged, replace the strainer.

14. Install the lines (4), (5) and cover (6).

NOTE: Use a new gasket under the cover (6) when reinstalling.

15. Connect the oil level sensor (3).

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16. Install the filter cover (2).

17. Connect the clogged filter sensor (1).

SS12E065

8

SS12E064

9

18. Install the cover.

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Accumulator - Remove 1. Drain the hydraulic oil.

NOTE: If the pressure is less than 120 bar (1740 psi) after periodic check at 1000 hours (according to the Operator's Manual), the pressure should be corrected by an authorized service department. If it is not possible to fill the pressure, the hydraulic accumulator must be replaced.

SS12N073

1

SS12N207

2

SS12N244

3

SS12N245

4

2. Remove the bolts and take out the floor cover. Lift off the automatic-transmission maintenance cover.

3. Remove the accumulator pipes.

4. Remove the accumulator from its holder.

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Index Hydraulic systems - 35 Reservoir, cooler, and filters - 300 Accumulator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Oil filters - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Oil reservoir - Change fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Oil reservoir - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

PRINTED IN U.S.A. © 2015 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

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

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

47703681 09/09/2015 EN

SERVICE MANUAL Pneumatic system PT240

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Contents Pneumatic system - 36

[36.100] Pneumatic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.1

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Pneumatic system - 36 Pneumatic system - 100

PT240

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Contents Pneumatic system - 36 Pneumatic system - 100

SERVICE Pneumatic system dryer Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Pneumatic system - Pneumatic system

Pneumatic system dryer - Remove 1. Let the air out via the blow-off valve on the air tank.

SS12D625

1

SS12N207

2

SS12N239

3

SS12N240

4

2. Remove the bolts and take out the floor cover. Lift off the automatic-transmission maintenance cover.

3. Detach the air distribution hoses and move them aside.

4. Remove the pipe clamp.

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Pneumatic system - Pneumatic system

5. Remove the pipe.

SS12N241

5

SS12N242

6

SS12N243

7

6. Remove the clamp.

7. Remove the dryer bracket, take it out of the machine, and then remove the dryer from the bracket.

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Index Pneumatic system - 36 Pneumatic system - 100 Pneumatic system dryer - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

PRINTED IN U.S.A. © 2015 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

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

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

47703681 09/09/2015 EN

SERVICE MANUAL Frames and ballasting PT240

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39

Contents Frames and ballasting - 39

[39.500] Vibratory roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1

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Frames and ballasting - 39 Vibratory roller - 500

PT240

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Contents Frames and ballasting - 39 Vibratory roller - 500

SERVICE Compaction - edge cutter Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Frames and ballasting - Vibratory roller

Compaction - edge cutter - Remove 1. Remove the hydraulic pipes.

SS12N266

1

SS12N267

2

SS12N714

3

SS12N715

4

2. Support the arm, remove the packing piece (A) used to mount the hydromotor, drive out the pin (B), and take out the hydromotor.

3. Remove the cutting wheel.

NOTE: Support in case the arm is unable to lower.

4. Remove the sprinkler.

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Frames and ballasting - Vibratory roller

5. Remove the clamp.

SS12N716

5

SS12N717

6

SS12N718

7

SS12N719

8

6. Remove the packing piece (A), drive out the pin (B), and remove the pipe (C).

7. Swing the hydromotor, lift the arm slightly to access the bolts used for mounting to the frame, and remove the four bolts used for mounting the arm to the frame.

8. Put aside the removed arm.

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Frames and ballasting - Vibratory roller

9. Support, install 2 bolts from below (use those obtained during pulley removal), and secure against rotation with a bar (A).

SS12N720

9

10. Remove the cover, unlock the washer, use the jig (1) (refer to Special tools ()) to remove the nut KM 10.

SS12N721

10

SS12N722

11

11. Use an ejector to tap out the bearing seat, incl. pin.

For replacement of packing material designed for the hydromotor, refer to Steering cylinder - Remove (41.216).

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Index Frames and ballasting - 39 Vibratory roller - 500 Compaction - edge cutter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

PRINTED IN U.S.A. © 2015 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

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

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

47703681 09/09/2015 EN

SERVICE MANUAL Steering PT240

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41

Contents Steering - 41

[41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1 [41.106] Tie rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 [41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3 [41.206] Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.4 [41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.5

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Steering - 41 Steering control - 101

PT240

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Contents Steering - 41 Steering control - 101

SERVICE Steering column Remove – Power steering servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

DIAGNOSTIC Steering control Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Steering - Steering control

Steering column - Remove – Power steering servo 1. Remove the cover from the panel.

Underneath the panel, disconnect the hoses from the steering servo – mark the hose connections before removal!

Remove the steering servo from the steering column.

SS13A020

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1

Steering - Steering control

Steering column - Remove 1. Remove the cover in the center of the steering column.

Unscrew the nut (A), insert jig no. (1) (refer to Special tools ()) under the steering wheel, and use the puller to take off the steering wheel.

SS12N748

1

SS13A021

2

SS13A022

3

2. Remove the travel controller sleeve (B).

3. With the bolts (C) removed, detach the steering servo and remove the steering column by the lower end.

NOTE: Lubricate the grooved shaft of the column with grease, when reinstalling.

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Steering - Steering control

Steering control - Troubleshooting Problem Steering does not respond.

Power steering steers in only one direction.

Steering is difficult

Possible Cause Low oil

Correction • Check the oil level.

• Check for leaks.

• Check the system pressure.

Defect in the check valve of power steering 1. Check the system pressure. valve block.

2. Check the functionality of the check valve.

Defective priority valve is causing low pres- Turn the steering wheel in one direction to the maximum limit and check the steering sure. pressure.

Defective pump is causing low pressure. Turn the steering wheel in one direction to the maximum limit and check the steering pressure.

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Index Steering - 41 Steering control - 101 Steering column - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Steering column - Remove – Power steering servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Steering control - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Steering - 41 Tie rods - 106

PT240

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Contents Steering - 41 Tie rods - 106

FUNCTIONAL DATA Tie rods Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Tie rods Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Steering - Tie rods

Tie rods - Component identification

SS12N732

Position 3 4 7 8 9 10 11 12 13

Designation Pin with flange Steering lever Pin Ring Ring Washer Washer Bush Bolt

1

Position 17 18 19 25 27 30 34 37 40

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Designation Connecting rod Locking ring Grease nipple Spring washer Spring washer Nut Bolt Cap Steel wire

Steering - Tie rods

Tie rods - Remove NOTE: For more details, refer to Tie rods - Component identification (41.106).

1. Release the split pin.

2. Unscrew the nuts from the connecting rod (17).

3. Separate the tie rod from the steering lever (4).

SS12N733

1

SS12N734

2

SS12N735

3

SS12N736

4

4. Unlock and unscrew the bolts (13).

5. Remove the washer (10).

6. Take the steering lever (4) off the pin along with the steering pull rods.

7. Remove the nuts (30).

8. Remove the bolts (34) from the holes along the perimeter of the pin (3).

9. Remove the pin (3) from the frame.

10. Press out the bronze bush (12) under the press.

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Steering - Tie rods

Tie rods - Install NOTE: For more details, refer to Tie rods - Component identification (41.106).

1. Press the bushing (12) into the steering lever (4).

SS12N736

1

SS12N737

2

SS12N749

3

2. Drive the ball joints of the connecting rods (17) into the taper pins of the steering lever (4), and tighten them.

3. Drive the pin (3) into the frame.

4. Use the bolts to connect the pin (3) to the frame.

5. Install the ring (9) onto the pin (3) along with the steering lever (4) and the second ring (9).

6. Install the lock washer (10), and secure it with the bolts (13).

7. Use a wire to secure the bolts from turning.

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Steering - Tie rods

8. Insert the fixing eye of the cylinder into the frame holder.

9. Insert two rings in the center.

10. Drive the pin (A) into the hole and secure with the safety ring (B).

SS13A895

4

SS13A894

5

11. Shift the piston rod out and insert two rings in the center.

12. Install the pin (F), and lock with the safety ring (C).

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Index Steering - 41 Tie rods - 106 Tie rods - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Tie rods - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Tie rods - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Steering - 41 Hydraulic control components - 200

PT240

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Contents Steering - 41 Hydraulic control components - 200

TECHNICAL DATA Hydraulic steering system Compressor - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Main priority valve Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Steering - Hydraulic control components

Compressor - General specification

SS12N728

1

Test ports Test port Steering system (1) Compressor system (2)

Pressure 140 bar (2030 psi) 210 bar (3045 psi)

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Steering - Hydraulic control components

Main priority valve - Static description Connect the valve in the hydraulic circuit for energy savings. The priority valve operates like a three-way relief valve to rectify oil flow to the tank with no losses when both steering wheels are at rest. The priority valve runs independently of pressure in the steering.

A logic valve has been engaged in the circuit as well.

The logic valve opens the hydraulic circuit for steering after receiving an impulse from power steering enabled via steering wheel movement.

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Index Steering - 41 Hydraulic control components - 200 Compressor - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Main priority valve - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Steering - 41 Pump - 206

PT240

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Contents Steering - 41 Pump - 206

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

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Steering - Pump

Pump - Remove 1. Drain the hydraulic oil.

SS12N073

1

SS12N378

2

SS12N237

3

SS12N379

4

2. Remove the discharge pipe.

3. Remove the discharge flange.

4. Remove and plug the suction hose.

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Steering - Pump

5. Remove the suction flange.

SS12N238

5

SS12N326

6

6. Remove the pump.

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Steering - Pump

Pump - Install 1. Install the pump.

NOTE: Replace the O-ring during installation.

2. Torque the bolts. Refer to Torque ()

SS12N326

1

SS12N238

2

SS12N379

3

SS12N237

4

3. Install the suction flange.

4. Install the suction hose.

5. Install the discharge flange.

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Steering - Pump

6. Install the discharge pipe.

SS12N378

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5

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

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Steering - 41 Cylinders - 216

PT240

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Contents Steering - 41 Cylinders - 216

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

SERVICE Steering cylinder Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Steering - Cylinders

Steering cylinder - Component identification Replace packing materials designed for the steering cylinder.

Packing material sets Position 1 2 3 4 5 6

Designation Gasket T19 Cuff T20 Scraper ring Guide band Ring Ring SS12N445

1

SS12N446

2

Cylinder Position 1 2 3 4 5

Designation Cylinder body Piston rod Piston Nut Cover

Cylinder torque table Piston rod (2), piston (3), nut (4) connection Torque Thread 130 N·m (96 lb ft) M30x2

Thread M85x1.5

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Cylinder body (1), Cylinder cover (5) Torque 180 N·m (133 lb ft)

Steering - Cylinders

Steering cylinder - Remove 1. Position the cylinder on a paved, level surface and position a drip pan under the steering cylinder.

2. Remove the high-pressure hoses.

SS12N729

1

SS12N730

2

SS12N731

3

3. Remove the safety rings (B), (C) and grease nipples (D), (E) for the pins (A), (F).

4. Remove the pins, and shift the steering cylinder out from the steering lever bracket.

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Steering - Cylinders

Steering cylinder - Disassemble 1. Unlock the hydromotor cover.

SS12K540

1

SS12N775

2

SS12K542

3

SS12K543

4

2. Use a hook wrench to remove the hydromotor cover (jig (2); refer to Special tools ()).

3. Take the hydromotor cover out.

4. Take the piston out of the hydromotor.

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Steering - Cylinders

5. Remove the piston nut and reseal (recaulk) the piston together with the cover.

SS12K544

5

SS12N776

6

SS12K546

7

SS12K547

8

6. Mount the jig (3) (refer to Special tools ()) in the hydromotor body.

7. Insert the piston.

8. Remove the jig from the hydromotor.

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Steering - Cylinders

9. Install the hydromotor cover.

NOTE: For tightening torques, refer to Steering cylinder Component identification (41.216).

SS12K548

9

10. Lock the cover.

SS12K549

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10

Steering - Cylinders

Steering cylinder - Filling 1. Remove the front cover plate. With the axle reinstalled on the machine, fill the hydromotors with oil to provide for leveling. Suspend the cylinder on a lifting device and lift to ensure the extent of shifting out the shaft from the hydromotor, (B) = 288.00 - 294.00 mm (11.34 - 11.57 in).

SS13A058

1

SS13A121

2

SS13A058

3

2. Mount the filling device to the quick coupling for filling.

The filling device must cover the following parameters: min. pressure of 6 MPa (870 psi), 3 to 10 μm filtration.

(Contact your authorized dealer for more information about filling equipment). Filling by means the filling device guarantees quality hydraulic oil without mechanical impurities.

3. When filled, lower the cylinder back to the ground and check (B) = 288.00 - 294.00 mm (11.34 - 11.57 in) extent.

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Index Steering - 41 Cylinders - 216 Steering cylinder - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Steering cylinder - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Steering cylinder - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Steering cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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

PRINTED IN U.S.A. © 2015 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

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

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

47703681 09/09/2015 EN

SERVICE MANUAL Wheels PT240

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Contents Wheels - 44

[44.511] Front wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1 [44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2

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Wheels - 44 Front wheels - 511

PT240

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Contents Wheels - 44 Front wheels - 511

TECHNICAL DATA Front wheels Tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Front wheels Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Wheels - Front wheels

Front wheels - Tire pressure WARNING Explosion hazard!

Always maintain correct tire pressure as indicated in this manual. DO NOT inflate tires above the recommended pressure. Excessive pressure could result in tire failure.

Failure to comply could result in death or serious injury.

W0109A

1. Check the pressure of tires inflated as required for operation based on the values in the table when cold (before driving) at temperatures of 18 - 21 °C (64 - 70 °F).

2. Connect the tire inflation hose to the mounted adapter instead of the tire inflation valve on the standard version of the roller. A pressure gauge, complete with inflation hose, is included in the machine equipment.

NOTICE: When inflating, check the following: The valve and whether it has a protective cap. The external condition of the tires and whether there is damage (due to local deformation, part of rubber separated, cracks, fissures).

SS12E014

1

Contact area and effective load depending on wheel load and tire inflation

11.00-20 / 18 PLY compactor without pattern 3 bar (43.5 psi) 4 bar (58 psi) Tire inflation bar (psi)

5 bar (72.5 psi) 6 bar (87 psi) 7 bar (101.5 psi) 8 bar (116 psi)

11.00-20 / 18 PLY compactor without pattern 3 bar (43.5 psi) 4 bar (58 psi) Tire inflation bar (psi)

5 bar (72.5 psi) 6 bar (87 psi) 7 bar (101.5 psi) 8 bar (116 psi)

Contact area m² (ft²) Load per one wheel - kg (lb) 1300 kg 1500 kg 2000 kg 2500 kg (2866 lb) (3307 lb) (4409 lb) (5512 lb) 0.0409 m² 0.0442 m² 0.0531 m² 0.0605 m² (0.44 ft²) (0.48 ft²) (0.57 ft²) (0.65 ft²) 0.0385 m² 0.0416 m² 0.0495 m² 0.0570 m² (0.41 ft²) (0.45 ft²) (0.53 ft²) (0.61 ft²) 0.0358 m² 0.0390 m² 0.0464 m² 0.0537 m² (0.39 ft²) (0.42 ft²) (0.50 ft²) (0.58 ft²) 0.0334 m² 0.0364 m² 0.0434 m² 0.0507 m² (0.36 ft²) (0.39 ft²) (0.47 ft²) (0.55 ft²) 0.0311 m² 0.0345 m² 0.0425 m² 0.0496 m² (0.33 ft²) (0.37 ft²) (0.46 ft²) (0.53 ft²) 0.0292 m² 0.0328 m² 0.0399 m² 0.0463 m² (0.31 ft²) (0.35 ft²) (0.43 ft²) (0.50 ft²)

3000 kg (6614 lb) 0.0688 m² (0.74 ft²) 0.0642 m² (0.69 ft²) 0.0600 m² (0.65 ft²) 0.0560 m² (0.60 ft²) 0.0541 m² (0.58 ft²) 0.0512 m² (0.55 ft²)

Effective load - kg/cm² (lb/ft²) Load per one wheel - kg (lb) 1300 kg 1500 kg 2000 kg 2500 kg (2866 lb) (3307 lb) (4409 lb) (5512 lb) 3.18 kg/cm² 3.39 kg/cm² 3.77 kg/cm² 4.13 kg/cm² (6513 lb/ft²) (6943 lb/ft²) (7722 lb/ft²) (8459 lb/ft²) 3.38 kg/cm² 3.61 kg/cm² 4.04 kg/cm² 4.39 kg/cm² (6922 lb/ft²) (7393 lb/ft²) (8275 (lb/ft²) (8991 lb/ft²) 3.63 kg/cm² 3.85 kg/cm² 4.31 kg/cm² 4.66 kg/cm² (7434 lb/ft²) (7885lb/ft²) (8828 lb/ft²) (9544 lb/ft²) 3.89 kg/cm² 4.12 kg/cm² 4.61 kg/cm² 4.93 kg/cm² (7967 lb/ft²) (8438 lb/ft²) (9442 lb/ft²) (10097 lb/ft²) 4.18 kg/cm² 4.35 kg/cm² 4.71 kg/cm² 5.04 kg/cm² (8561 lb/ft²) (8910 lb/ft²) (9647 lb/ft²) (10322 lb/ft²) 4.45 kg/cm² 4.57 kg/cm² 5.01 kg/cm² 5.40 kg/cm² (9114 lb/ft²) (9360 lb/ft²) (10261 lb/ft²) (11060 lb/ft²)

3000 kg (6614 lb) 4.36 kg/cm² (8930 lb/ft²) 4.67 kg/cm² (9565 lb/ft²) 5.00 kg/cm² (10241 lb/ft²) 5.36 kg/cm² (10978 lb/ft²) 5.55 kg/cm² (11367 lb/ft²) 5.86 kg/cm² (12002 lb/ft²)

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Wheels - Front wheels

Front wheels - Torque DANGER Heavy objects!

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

Failure to comply will result in death or serious injury.

D0076A

WARNING Unexpected movement!

Secure the machine to prevent inadvertent movements.

Failure to comply could result in death or serious injury.

W1060A

1. Torque the lug nuts (A) in a star pattern as shown in Figure 1. Torque the lug nuts (A) to 400.0 N·m (295.0 lb ft).

NOTICE: Make sure to check the torque on the lug nuts (A) after every two hours of operation until the torque stabilizes.

RAPH15COM0330BA

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1

Wheels - Front wheels

Front wheels - Remove DANGER Heavy objects!

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

Failure to comply will result in death or serious injury.

D0076A

WARNING Explosion hazard!

When inflating tires, use a clip-on air chuck with a gauge, remote valve, and hose long enough to allow you to stand to one side and NOT in front of or over the wheel assembly. Keep others out of the DANGER AREA. Never inflate a tire beyond the maximum allowable pressure printed on the tire.

Failure to comply could result in death or serious injury.

W0059A

WARNING Unexpected movement!

Secure the machine to prevent inadvertent movements.

Failure to comply could result in death or serious injury.

W1060A

1. Park the machine on a level, paved surface.

2. Secure the rear wheels with chocks on both sides.

3. Turn the battery master disconnect switch to OFF. NOTE: Once the power is removed, the machine brake will engage automatically.

4. Position warning signs around work area to signal machine is out of operation.

5. If equipped, remove the front thermal insulation apron for tire access.

RAPH15COM0333AA

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1

Wheels - Front wheels

6. If equipped, remove the tire scraper, shown by arrows, to allow for the tire removal.

7. Loosen the eight lug nuts (A) on the tire.

NOTE: Do not remove the lugs completely.

RAPH15COM0329BA

2

RAPH15COM0332BA

3

RAPH15COM0331BA

4

8. Relieve the tire pressure from the tire completely. See Front wheels - Tire pressure (44.511) for further information on the tire pressures.

9. Remove the air line (B) and the rotor (C) from the tire.

10. Lift the front of the machine up from the ground so that the tires are approximately 50.0 mm (2.0 in) from the ground.

11. Place the supports under the machine frame for safety.

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Wheels - Front wheels

12. Remove the lug nuts (A) from the tire, and remove the tire from machine using appropriate lifting device.

NOTE: The tire is heavy, procure a helper to assist in the removal procedure.

RAPH15COM0329BA

13. If the tire is defective, have the tire serviced by a certified tire repair specialist.

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5

Wheels - Front wheels

Front wheels - Install DANGER Heavy objects!

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

Failure to comply will result in death or serious injury.

D0076A

WARNING Explosion hazard!

When inflating tires, use a clip-on air chuck with a gauge, remote valve, and hose long enough to allow you to stand to one side and NOT in front of or over the wheel assembly. Keep others out of the DANGER AREA. Never inflate a tire beyond the maximum allowable pressure printed on the tire.

Failure to comply could result in death or serious injury.

W0059A

WARNING Unexpected movement!

Secure the machine to prevent inadvertent movements.

Failure to comply could result in death or serious injury.

W1060A

1. Install the tire onto the wheel hub assembly, and secure the tire with eight tire lug nuts (A).

NOTE: The tire is heavy, procure a helper to assist in the installation procedure.

RAPH15COM0329BA

1

RAPH15COM0330BA

2

2. Torque the lug nuts (A) in a star pattern as shown in Figure 2. Torque the lug nuts (A) to 400.0 N·m (295.0 lb ft).

NOTE: Make sure to check the torque again and adjust every two hours of operation until the torque stabilizes.

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Wheels - Front wheels

3. Install the air line (B) and the rotor (C) onto the tire.

RAPH15COM0332BA

3

RAPH15COM0331BA

4

RAPH15COM0329BA

5

4. Lift the front of the machine off of the supports, and then remove the supports.

5. Lower the machine down to the ground.

6. Remove the rear wheel chocks from both sides of the machine.

7. Set the tire pressure to the tire per the application. See Front wheels - Tire pressure (44.511) for further information on the tire pressures.

8. If equipped, install the scraper onto the machine, and set the scraper to the tire.

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Wheels - Front wheels

9. If equipped, install the front thermal insulation apron onto the machine.

RAPH15COM0333AA

After 2 hours of operation 10. Check the torque of the lug nuts on the tire per instruction 2, and repeat every 2 hours until the torque on each lug is stabilized.

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6

Index Wheels - 44 Front wheels - 511 Front wheels - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Front wheels - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Front wheels - Tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Front wheels - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Wheels - 44 Rear wheels - 520

PT240

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Contents Wheels - 44 Rear wheels - 520

TECHNICAL DATA Rear wheels Tire pressure - Central Air Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Rear wheel Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Wheels - Rear wheels

Rear wheels - Tire pressure - Central Air Inflation WARNING Explosion hazard!

Always maintain correct tire pressure as indicated in this manual. DO NOT inflate tires above the recommended pressure. Excessive pressure could result in tire failure.

Failure to comply could result in death or serious injury.

W0109A

1. Check the pressure (B) of the tires inflated as required for operation based on the values in the table when cold (before driving) at temperatures of 18 - 21 °C (64 - 70 °F).

2. The tire inflation control (C) and deflation control (D) are used to inflate or deflate the tires with air shown in view (A).

NOTICE: When inflating or deflating: Do not switch ON both valves simultaneously to the I position!

RAPH15COM0336HA

1

Contact area and effective load depending on wheel load and tire inflation

11.00-20 / 18 PLY compactor without pattern 3 bar (43.5 psi) 4 bar (58 psi) Tire inflation bar (psi)

5 bar (72.5 psi) 6 bar (87 psi) 7 bar (101.5 psi) 8 bar (116 psi)

11.00-20 / 18 PLY compactor without pattern

Contact area m² (ft²) Load per one wheel - kg (lb) 1300 kg 1500 kg 2000 kg 2500 kg (2866 lb) (3307 lb) (4409 lb) (5512 lb) 0.0409 m² 0.0442 m² 0.0531 m² 0.0605 m² (0.44 ft²) (0.48 ft²) (0.57 ft²) (0.65 ft²) 0.0385 m² 0.0416 m² 0.0495 m² 0.0570 m² (0.41 ft²) (0.45 ft²) (0.53 ft²) (0.61 ft²) 0.0358 m² 0.0390 m² 0.0464 m² 0.0537 m² (0.39 ft²) (0.42 ft²) (0.50 ft²) (0.58 ft²) 0.0334 m² 0.0364 m² 0.0434 m² 0.0507 m² (0.36 ft²) (0.39 ft²) (0.47 ft²) (0.55 ft²) 0.0311 m² 0.0345 m² 0.0425 m² 0.0496 m² (0.33 ft²) (0.37 ft²) (0.46 ft²) (0.53 ft²) 0.0292 m² 0.0328 m² 0.0399 m² 0.0463 m² (0.31 ft²) (0.35 ft²) (0.43 ft²) (0.50 ft²)

3000 kg (6614 lb) 0.0688 m² (0.74 ft²) 0.0642 m² (0.69 ft²) 0.0600 m² (0.65 ft²) 0.0560 m² (0.60 ft²) 0.0541 m² (0.58 ft²) 0.0512 m² (0.55 ft²)

Effective load - kg/cm² (lb/ft²) Load per one wheel - kg (lb) 1300 kg 1500 kg 2000 kg 2500 kg (2866 lb) (3307 lb) (4409 lb) (5512 lb)

3000 kg (6614 lb)

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Wheels - Rear wheels

3 bar (43.5 psi) 4 bar (58 psi) Tire inflation bar (psi)

5 bar (72.5 psi) 6 bar (87 psi) 7 bar (101.5 psi) 8 bar (116 psi)

Effective load - kg/cm² (lb/ft²) 3.18 kg/cm² 3.39 kg/cm² 3.77 kg/cm² (6513 lb/ft²) (6943 lb/ft²) (7722 lb/ft²) 3.38 kg/cm² 3.61 kg/cm² 4.04 kg/cm² (6922 lb/ft²) (7393 lb/ft²) (8275 (lb/ft²) 3.63 kg/cm² 3.85 kg/cm² 4.31 kg/cm² (7434 lb/ft²) (7885lb/ft²) (8828 lb/ft²) 3.89 kg/cm² 4.12 kg/cm² 4.61 kg/cm² (7967 lb/ft²) (8438 lb/ft²) (9442 lb/ft²) 4.18 kg/cm² 4.35 kg/cm² 4.71 kg/cm² (8561 lb/ft²) (8910 lb/ft²) (9647 lb/ft²) 4.45 kg/cm² 4.57 kg/cm² 5.01 kg/cm² (9114 lb/ft²) (9360 lb/ft²) (10261 lb/ft²)

4.13 kg/cm² (8459 lb/ft²) 4.39 kg/cm² (8991 lb/ft²) 4.66 kg/cm² (9544 lb/ft²) 4.93 kg/cm² (10097 lb/ft²) 5.04 kg/cm² (10322 lb/ft²) 5.40 kg/cm² (11060 lb/ft²)

4.36 kg/cm² (8930 lb/ft²) 4.67 kg/cm² (9565 lb/ft²) 5.00 kg/cm² (10241 lb/ft²) 5.36 kg/cm² (10978 lb/ft²) 5.55 kg/cm² (11367 lb/ft²) 5.86 kg/cm² (12002 lb/ft²)

Rear wheels - Tire pressure WARNING Explosion hazard!

Always maintain correct tire pressure as indicated in this manual. DO NOT inflate tires above the recommended pressure. Excessive pressure could result in tire failure.

Failure to comply could result in death or serious injury.

W0109A

1. Check the pressure of tires inflated as required for operation based on the values in the table when cold (before driving) at temperatures of 18 - 21 °C (64 - 70 °F).

2. Connect the tire inflation hose to the mounted adapter instead of the tire inflation valve on the standard version of the roller. A pressure gauge, complete with inflation hose, is included in the machine equipment.

NOTICE: When inflating, check the following: The valve and whether it has a protective cap. The external condition of the tires and whether there is damage (due to local deformation, part of rubber separated, cracks, fissures).

SS12E014

1

Contact area and effective load depending on wheel load and tire inflation

11.00-20 / 18 PLY compactor without pattern 3 bar (43.5 psi) 4 bar (58 psi) Tire inflation bar (psi)

5 bar (72.5 psi) 6 bar (87 psi) 7 bar (101.5 psi) 8 bar (116 psi)

Contact area m² (ft²) Load per one wheel - kg (lb) 1300 kg 1500 kg 2000 kg 2500 kg (2866 lb) (3307 lb) (4409 lb) (5512 lb) 0.0409 m² 0.0442 m² 0.0531 m² 0.0605 m² (0.44 ft²) (0.48 ft²) (0.57 ft²) (0.65 ft²) 0.0385 m² 0.0416 m² 0.0495 m² 0.0570 m² (0.41 ft²) (0.45 ft²) (0.53 ft²) (0.61 ft²) 0.0358 m² 0.0390 m² 0.0464 m² 0.0537 m² (0.39 ft²) (0.42 ft²) (0.50 ft²) (0.58 ft²) 0.0334 m² 0.0364 m² 0.0434 m² 0.0507 m² (0.36 ft²) (0.39 ft²) (0.47 ft²) (0.55 ft²) 0.0311 m² 0.0345 m² 0.0425 m² 0.0496 m² (0.33 ft²) (0.37 ft²) (0.46 ft²) (0.53 ft²) 0.0292 m² 0.0328 m² 0.0399 m² 0.0463 m² (0.31 ft²) (0.35 ft²) (0.43 ft²) (0.50 ft²)

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3000 kg (6614 lb) 0.0688 m² (0.74 ft²) 0.0642 m² (0.69 ft²) 0.0600 m² (0.65 ft²) 0.0560 m² (0.60 ft²) 0.0541 m² (0.58 ft²) 0.0512 m² (0.55 ft²)

Wheels - Rear wheels

11.00-20 / 18 PLY compactor without pattern 3 bar (43.5 psi) 4 bar (58 psi) Tire inflation bar (psi)

5 bar (72.5 psi) 6 bar (87 psi) 7 bar (101.5 psi) 8 bar (116 psi)

Effective load - kg/cm² (lb/ft²) Load per one wheel - kg (lb) 1300 kg 1500 kg 2000 kg 2500 kg (2866 lb) (3307 lb) (4409 lb) (5512 lb) 3.18 kg/cm² 3.39 kg/cm² 3.77 kg/cm² 4.13 kg/cm² (6513 lb/ft²) (6943 lb/ft²) (7722 lb/ft²) (8459 lb/ft²) 3.38 kg/cm² 3.61 kg/cm² 4.04 kg/cm² 4.39 kg/cm² (6922 lb/ft²) (7393 lb/ft²) (8275 (lb/ft²) (8991 lb/ft²) 3.63 kg/cm² 3.85 kg/cm² 4.31 kg/cm² 4.66 kg/cm² (7434 lb/ft²) (7885lb/ft²) (8828 lb/ft²) (9544 lb/ft²) 3.89 kg/cm² 4.12 kg/cm² 4.61 kg/cm² 4.93 kg/cm² (7967 lb/ft²) (8438 lb/ft²) (9442 lb/ft²) (10097 lb/ft²) 4.18 kg/cm² 4.35 kg/cm² 4.71 kg/cm² 5.04 kg/cm² (8561 lb/ft²) (8910 lb/ft²) (9647 lb/ft²) (10322 lb/ft²) 4.45 kg/cm² 4.57 kg/cm² 5.01 kg/cm² 5.40 kg/cm² (9114 lb/ft²) (9360 lb/ft²) (10261 lb/ft²) (11060 lb/ft²)

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3000 kg (6614 lb) 4.36 kg/cm² (8930 lb/ft²) 4.67 kg/cm² (9565 lb/ft²) 5.00 kg/cm² (10241 lb/ft²) 5.36 kg/cm² (10978 lb/ft²) 5.55 kg/cm² (11367 lb/ft²) 5.86 kg/cm² (12002 lb/ft²)

Wheels - Rear wheels

Rear wheel - Remove DANGER Heavy objects!

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

Failure to comply will result in death or serious injury.

D0076A

WARNING Explosion hazard!

When inflating tires, use a clip-on air chuck with a gauge, remote valve, and hose long enough to allow you to stand to one side and NOT in front of or over the wheel assembly. Keep others out of the DANGER AREA. Never inflate a tire beyond the maximum allowable pressure printed on the tire.

Failure to comply could result in death or serious injury.

W0059A

WARNING Unexpected movement!

Secure the machine to prevent inadvertent movements.

Failure to comply could result in death or serious injury.

W1060A

1. Park the machine on a level, paved surface.

2. Secure the front wheels with chocks on both sides.

3. Turn the battery master disconnect switch to OFF. NOTE: Once the power is removed, the machine brake will engage automatically.

4. Position warning signs around work area to signal machine is out of operation.

5. If equipped, remove the rear thermal insulation apron for tire access.

RAPH15COM0333AA

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1

Wheels - Rear wheels

6. If equipped, remove the tire scraper, shown by the arrow, to allow for the tire removal.

7. Loosen the eight lug nuts (A) on the tire.

NOTE: Do not remove the lugs completely.

RAPH15COM0334BA

2

RAPH15COM0334BA

3

RAPH15COM0335AA

4

8. Relieve the tire pressure from the tire completely. See Rear wheels - Tire pressure (44.520) or Rear wheels - Tire pressure - Central Air Inflation (44.520) for further information on the tire pressures.

9. Remove the air line (B) and the rotor (C) from the tire.

10. Lift the rear of the machine up from the ground so that the tires are approximately 50.0 mm (2.0 in) from the ground.

11. Place the supports under the machine frame for safety.

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Wheels - Rear wheels

12. Remove the lug nuts (A) from the tire, and remove the tire from the machine using appropriate lifting device.

NOTE: The tire is heavy, procure a helper to assist in the removal procedure.

RAPH15COM0334BA

13. If the tire is defective, have the tire serviced by a certified tire repair specialist.

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5

Wheels - Rear wheels

Rear wheel - Install DANGER Heavy objects!

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

Failure to comply will result in death or serious injury.

D0076A

WARNING Explosion hazard!

When inflating tires, use a clip-on air chuck with a gauge, remote valve, and hose long enough to allow you to stand to one side and NOT in front of or over the wheel assembly. Keep others out of the DANGER AREA. Never inflate a tire beyond the maximum allowable pressure printed on the tire.

Failure to comply could result in death or serious injury.

W0059A

WARNING Unexpected movement!

Secure the machine to prevent inadvertent movements.

Failure to comply could result in death or serious injury.

W1060A

1. Install the tire onto the wheel hub assembly, and secure the tire with eight tire lug nuts (A).

NOTE: The tire is heavy, procure a helper to assist in the installation procedure.

RAPH15COM0334BA

1

RAPH15COM0330BA

2

2. Torque the lug nuts (A) in a star pattern as shown in Figure 2. Torque the lug nuts (A) to 400.0 N·m (295.0 lb ft).

NOTE: Make sure to check the torque again and adjust every two hours of operation until the torque stabilizes.

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Wheels - Rear wheels

3. Install the air line (B) and the rotor (C) onto the tire.

RAPH15COM0334BA

3

RAPH15COM0335AA

4

RAPH15COM0334BA

5

4. Lift the rear of the machine off of the supports, and then remove the supports.

5. Lower the machine down to the ground.

6. Remove the front wheel chocks from both sides of the machine.

7. Set the tire pressure to the tire per the application. See Rear wheels - Tire pressure (44.520) or Rear wheels - Tire pressure - Central Air Inflation (44.520) for further information on the tire pressures.

8. If equipped, install the scraper onto the machine, and set the scraper to the tire.

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Wheels - Rear wheels

9. If equipped, install the rear thermal insulation apron onto the machine.

RAPH15COM0333AA

After 2 hours of operation 10. Check the torque of the lug nuts on the tire per instruction 2, and repeat every 2 hours until the torque on each lug is stabilized.

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6

Index Wheels - 44 Rear wheels - 520 Rear wheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Rear wheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Rear wheels - Tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Rear wheels - Tire pressure - Central Air Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

PRINTED IN U.S.A. © 2015 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

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

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

47703681 09/09/2015 EN

SERVICE MANUAL Cab climate control PT240

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50

Contents Cab climate control - 50

[50.104] Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1 [50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2

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Cab climate control - 50 Ventilation - 104

PT240

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Contents Cab climate control - 50 Ventilation - 104

FUNCTIONAL DATA Cab air filters Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Cab climate control - Ventilation

Cab air filters - Component localization Position 1 2

Designation Cab induction air control Filter

SS13G033

1

SS12D594

2

The machine is also equipped with a filter for internal air circulation.

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Index Cab climate control - 50 Ventilation - 104 Cab air filters - Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Cab climate control - 50 Air conditioning - 200

PT240

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Contents Cab climate control - 50 Air conditioning - 200

TECHNICAL DATA Air conditioning General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Air conditioning Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Air conditioning Replace – Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

DIAGNOSTIC Air conditioning Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Cab climate control - Air conditioning

Air conditioning - General specification A/C system specifications Refrigerant Capacity Cut-off pressure for the high pressure switch Cut-off pressure for the low pressure switch Cut-off temperature of the freezing thermostat

R134A 1.1 kg (2.4 lb) 2.65 MPa (384 psi) 0.21 MPa (30 psi) 1 °C (34 °F)

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Cab climate control - Air conditioning

Air conditioning - Overview The air conditioner operates in a thermodynamic cycle, where heat is withdrawn on low-pressure side in the evaporator located inside the cabin behind driver’s seat, and the heat is transferred to the ambient air on the high-pressure side in the condenser located upstream.

The compressor induces vapors from the evaporator and expels these into the condenser. Inside the condenser, the vapors are under constant pressure, and this pressure alters their state from a gas to a liquid. This liquid flows to the filter-dehydrator —which has an inspection sight glass— into the thermostatic expansion valve (TEV). The TEV injects liquid refrigerant into the evaporator, where the heat is withdrawn from the environment. From here, the vapors are induced into compressor again.

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Cab climate control - Air conditioning

Air conditioning - Replace – Filter 1. Remove the cover grille on both sides.

SS13F358

1

SS13F359

2

2. Replace both filter elements.

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Cab climate control - Air conditioning

Air conditioning - Troubleshooting Problem A/C will not operate

Possible Cause Blow fuse Disconnected connector

Refrigerant leak A/C will not blow cold air Refrigerant too low Compressor clutch Evaporator fan has failed intermittently engages

Correction Check the fuse Check the electrical connections of the switches, relays, control module, and compressor Test for leaks Check for leaks 1. Check the fuse 2. Check the relay 3. Check for voltage and ground at the fan

4. Verify that the fan has movement and is not seized Freezing thermostat has failed Replace the freezing thermostat Low flow rate through the condenser is 1. Check the refrigerant level causing high pressure which is activating 2. Check the refrigerant quality the high pressure switch 3. Check the functionality of the compressor Broken low pressure switch Broken high pressure switch Refrigerant leak is causing low pressure which is activating the low pressure switch Electromagnet clutch in the compressor is worn

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4. Check for clogs in the system Replace the low pressure switch Replace the high pressure switch Check for leaks Replace the clutch or compressor assembly

Index Cab climate control - 50 Air conditioning - 200 Air conditioning - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Air conditioning - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Air conditioning - Replace – Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Air conditioning - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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

PRINTED IN U.S.A. © 2015 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

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

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

47703681 09/09/2015 EN

SERVICE MANUAL Electrical systems PT240

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Contents Electrical systems - 55

[55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.525] Cab engine controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.011] Fuel tank system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 [55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8 [55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9 [55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10 [55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11

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Electrical systems - 55 Electrical system - 000

PT240

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Contents Electrical systems - 55 Electrical system - 000

FUNCTIONAL DATA Electrical system Wiring harnesses - Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - Electrical system

Wiring harnesses - Component localization

SS13G133

1

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Electrical systems - Electrical system

Position B1 B2 B3 B4 E2, E3 E4, E5 E6, E7 E8, E9 E13, E14 E15-E17 E18-E20 G1 G2 H1 H11

Designation Accelerator pedal position switch Transmission temperature sensors Transmission lubrication pressure gauge sensor Fuel gauge float Front contour light Tail lights Headlights Tail headlights Brake lights Left-hand direction indicators Right-hand direction indicators Battery Alternator Horn Acoustic indicator for brake failure

Position S11 S12 S13 S16 S19 S20 S21 S22 S24 X34 Y1, Y2 Y3 Y4 Y5 Y6

M1

Starter

Y7

Q1

Master switch

Y8

S5

Brake light pressure switch

Y9

ECU

Engine control unit

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Designation Left-hand gear selector Right-hand gear selector Hydraulic tank float switch Differential lock switch (optional) Pressure switch for brake failure Pressure switch for brakes Hydraulic oil filter pressure switch Engine air filter pressure switch Hydraulic oil heater switch Field socket Electromagnets for valves, gear shifting Electromagnet for valves, forward travel Electromagnet for valves, rearward travel Electromagnet for brake valves Electromagnets for differential lock valve (optional) Electromagnetic clutch for air conditioner compressor (optional) Electromagnet for valve, edge cutter, upward (optional) Electromagnet for valve, edge cutter, downward (optional)

Index Electrical systems - 55 Electrical system - 000 Wiring harnesses - Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Harnesses and connectors - 100

PT240

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Contents Electrical systems - 55 Harnesses and connectors - 100

FUNCTIONAL DATA Wiring harnesses Harnesses and connectors - Electrical schema - A/C system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Electrical schema - Schematic one of two . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Electrical schema - Schematic two of two . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Fuse and relay box Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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Electrical systems - Harnesses and connectors

Harnesses and connectors - Electrical schema - A/C system Component description Position 1 2 3 4

Description Control panel Indoor temperature sensor Outdoor temperature sensor Pressure breaker

Position 5 6 7 8

RAIL14COM0519GA

1

A/C schematic

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Description Compressor coil Evaporator fan motor Switch Control module

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schema - Schematic one of two Schematic guide Line color Red Green Orange

Description Unswitched power Switched power Starting sequence

Component description Position A1 A2 A3 B1 B2 B3 B4 C1 E1 E2, E3 E4, E5 E6, E7 E8, E9 E10 E11, E12 E13, E14 E15-E17 E18-E20 E21 F1-F21 G1 G2 H1 H2 H3 H4 H5 H6 H7 H8 H9 H10 H11

Description Light interrupter Steering changeover electronics Murphy multifunctional display, PV - 101 Accelerator pedal position switch Transmission temperature sensors Transmission pressure gauge sensor Fuel gauge float Interference filter Instrument lighting Front contour light Tail lights Headlights Tail headlights Hazard warning beacon (optional) Cab lighting Brake lights Left-hand direction indicators Right-hand direction indicators

Position Q1 R1, R2 R3 S1 S2 S3 S4 S5 S6, S7 S8 S9 S11 S12 S13 S14 S15 S16 S17

Reversing headlight (optional)

S18

Drop-out fuses Battery Alternator Horn Reversing horn (optional) Indicator light for direction indicators Indicator light for neutral Indicator light for right-hand steering Indicator light for left-hand steering Indicator light for hydraulic oil level Indicator light for engine preheating Indicator light for battery charging Indicator light for brake failure Acoustic indicator for brake failure

S19 S20 S21 S22 S24 S25 S26 S27 S28 S29 S30 S31 S32 S33

H12 H13 H14

Indicator light for brake Indicator light for clogged air filter Indicator light for clogged engine air filter

S34 V1, V2 X1-X33

H16 H17 K1-D3 K5-K8 K11-K13 M1

Indicator light for over-heating hydraulics Indicator light for sprinkling Auxiliary relay Auxiliary relay Contactors Starter

X34 X35, X36 X37 X38-X43 Y1, Y2 Y3

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Description Master switch Engine preheating Resistor Ignition switch Front headlight switch Tail headlight switch Hazard warning beacon switch (optional) Brake light pressure switch Horn buttons Hazard warning light switch Traffic indicator light changeover switch Left-hand gear selector Right-hand gear selector Hydraulic tank float switch Emergency brake button Parking brake switch Differential lock switch (optional) Indicator for engaged differential lock (optional) Double button to adjust engine idle speed Pressure switch for brake failure Pressure switch for brakes Hydraulic oil filter pressure switch Engine air filter pressure switch Hydraulic oil over-heating switch Rear window wiper changeover switch Rear window wiper switch Double button for windshield washers Sprinkling overpressure switch (optional) Cycling device for sprinkling Cooling air fan changeover switch Air conditioner switch (optional) Air conditioner thermostat (optional) Air conditioner overpressure safety device (optional) Double button for edge cutter (optional) Interlocking diodes Interconnecting connectors (X1, 11, 24, 32 and 33 are vacant) Field socket Engine connectors Engine diagnostics connectors Connectors J1939 Electromagnets for valves, gear shifting Electromagnet for valves, forward travel

Electrical systems - Harnesses and connectors

Position M2

Description Front windshield wiper

Position Y4

M3 M4

Rear window wiper Front windshield washer

Y5 Y6

M5

Rear window washer

Y7

M6

Sprinkling pump motor

Y8

Cooling air fans

Y9

M7-M9 P1 P2

Transmission thermometer Transmission lubrication pressure gauge

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Description Electromagnet for valves, rearward travel Electromagnet for brake valves Electromagnets for differential lock valve (optional) Electromagnetic clutch for air conditioner compressor (optional) Electromagnet for valve, edge cutter, upward (optional) Electromagnet for valve, edge cutter, downward (optional)

Electrical systems - Harnesses and connectors

Schematic one of two

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Electrical systems - Harnesses and connectors

RAIL14COM0517JA

1

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schema - Schematic two of two Schematic guide Line color Green

Description Switched power

Component description Position A1 A2 A3 B1 B2 B3 B4 C1 E1 E2, E3 E4, E5 E6, E7 E8, E9 E10 E11, E12 E13, E14 E15-E17 E18-E20 E21 F1-F21 G1 G2 H1 H2 H3 H4 H5 H6 H7 H8 H9 H10 H11

Description Light interrupter Steering changeover electronics Murphy multifunctional display, PV - 101 Accelerator pedal position switch Transmission temperature sensors Transmission pressure gauge sensor Fuel gauge float Interference filter Instrument lighting Front contour light Tail lights Headlights Tail headlights Hazard warning beacon (optional) Cab lighting Brake lights Left-hand direction indicators Right-hand direction indicators

Position Q1 R1, R2 R3 S1 S2 S3 S4 S5 S6, S7 S8 S9 S11 S12 S13 S14 S15 S16 S17

Reversing headlight (optional)

S18

Drop-out fuses Battery Alternator Horn Reversing horn (optional) Indicator light for direction indicators Indicator light for neutral Indicator light for right-hand steering Indicator light for left-hand steering Indicator light for hydraulic oil level Indicator light for engine preheating Indicator light for battery charging Indicator light for brake failure Acoustic indicator for brake failure

S19 S20 S21 S22 S24 S25 S26 S27 S28 S29 S30 S31 S32 S33

H12 H13 H14

Indicator light for brake Indicator light for clogged air filter Indicator light for clogged engine air filter

S34 V1, V2 X1-X33

H16 H17 K1-D3 K5-K8 K11-K13 M1 M2

Indicator light for over-heating hydraulics Indicator light for sprinkling Auxiliary relay Auxiliary relay Contactors Starter Front windshield wiper

X34 X35, X36 X37 X38-X43 Y1, Y2 Y3 Y4

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Description Master switch Engine preheating Resistor Ignition switch Front headlight switch Tail headlight switch Hazard warning beacon switch (optional) Brake light pressure switch Horn buttons Hazard warning light switch Traffic indicator light changeover switch Left-hand gear selector Right-hand gear selector Hydraulic tank float switch Emergency brake button Parking brake switch Differential lock switch (optional) Indicator for engaged differential lock (optional) Double button to adjust engine idle speed Pressure switch for brake failure Pressure switch for brakes Hydraulic oil filter pressure switch Engine air filter pressure switch Hydraulic oil over-heating switch Rear window wiper changeover switch Rear window wiper switch Double button for windshield washers Sprinkling overpressure switch (optional) Cycling device for sprinkling Cooling air fan changeover switch Air conditioner switch (optional) Air conditioner thermostat (optional) Air conditioner overpressure safety device (optional) Double button for edge cutter (optional) Interlocking diodes Interconnecting connectors (X1, 11, 24, 32 and 33 are vacant) Field socket Engine connectors Engine diagnostics connectors Connectors J1939 Electromagnets for valves, gear shifting Electromagnet for valves, forward travel Electromagnet for valves, rearward travel

Electrical systems - Harnesses and connectors

Position M3 M4

Description Rear window wiper Front windshield washer

Position Y5 Y6

M5

Rear window washer

Y7

M6

Sprinkling pump motor

Y8

Cooling air fans

Y9

M7-M9 P1 P2

Transmission thermometer Transmission lubrication pressure gauge

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Description Electromagnet for brake valves Electromagnets for differential lock valve (optional) Electromagnetic clutch for air conditioner compressor (optional) Electromagnet for valve, edge cutter, upward (optional) Electromagnet for valve, edge cutter, downward (optional)

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Schematic two of two

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Electrical systems - Harnesses and connectors

RAIL14COM0518JA

1

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Fuse and relay box - Component localization WARNING Avoid injury!

Shut off the engine, remove the key, and make sure all motion is stopped before servicing the machine.

Failure to comply could result in death or serious injury.

W1128A

NOTE: Always replace the fuses with ones of identical value!

SS12E227

Fuse location 1

Rating

Description

15 A

Mounting socket

2

15 A

3

15 A

4 5

15 A 5A

6 7

15 A 7.5 A

8

7.5 A

1

Fuse location 11

Rating

Description

5A

Tail headlights

12

1A

Beacon, brake lights, cab lighting, horn Direction indicators Front fender lights, tail lights, instrument lighting Headlights Transmission solenoids, reversing horn Differential lock solenoids, hydraulic oil level, engine start relay

13

15 A

Indicator lamps (LEDs), measuring instruments, brake failure Diagnostics, multifunctional display Wipers, washers

14 15

10 A 25 A

Sprinkling Fans

16 17

10 A

Air conditioner, edge cutter Spare

18

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Spare

Electrical systems - Harnesses and connectors

SS12E228

F9 F10

Rating 30 A

Description Engine Control Module (ECM) (9) Reserved for radio (10)

SS12E229

F19

Rating 125 A

Description Preheating (19)

2

F21

Rating 80 A

Description Main fuse (21)

Rating 125 A

Description Preheating (20)

3

F20

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Index Electrical systems - 55 Harnesses and connectors - 100 Fuse and relay box - Component localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Harnesses and connectors - Electrical schema - A/C system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Wiring harnesses - Electrical schema - Schematic one of two . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Wiring harnesses - Electrical schema - Schematic two of two . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Electrical systems - 55 Cab engine controls - 525

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Contents Electrical systems - 55 Cab engine controls - 525

SERVICE Accelerator potentiometer Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - Cab engine controls

Accelerator potentiometer - Adjust NOTE: Make the adjustment after the accelerator pedal position sensor has been replaced. Check after having replaced the engine injection pump or the multi-functional device for idle speed adjustment of 850 RPM in ENGINE RPM and the 82.4 % value in ACCELERATOR PEDAL (in ENGINE RPM this corresponds to max. 2200 RPM).

1. Remove the floor carpets near the left-hand accelerator pedal. Remove the cover and fold up the gearbox cover.

SS12N207

1

SS13A031

2

SS12C101

3

2. Heat the engine to ca 30 °C (86 °F), then stop the engine.

3. Press the MENU button to move from the four-parameter display to the main menu.

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Electrical systems - Cab engine controls

4. Press the ENTER button to move to GO TO 1 - UP DISPLAY.

SS12E237

4

SS13A033

5

SS13A035

6

SS13A036

7

5. Move the cursor to ACCELERATOR PEDAL.

6. Unlock the fork split pin (A) near the accelerator pedal.

7. Remove the fork split pin from the sensor lever (B) by swinging the sensor lever forward and backward.

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Electrical systems - Cab engine controls

8. Adjust the display value to 0.0.

SS13A033

8

SS13A037

9

9. Slip the pull rod fork back into the sensor lever and lock it.

10. Switch the cursor to ENGINE RPM.

SS13A038

10

SS13A039

11

11. Start the engine, use the IDLE switch (on the instrument board) to adjust the 850 RPM value.

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Electrical systems - Cab engine controls

12. Move the cursor to ACCELERATOR PEDAL.

SS13A033

12

SS13A040

13

SS13A041

14

13. Actuate the accelerator pedal to max RPM. Adjust nut (A) (the stop) for the throttle pull rod, lock with nut (B).

14. to have the 82.4 % value adjusted (after switching to ENGINE RPM with the cursor, 2200 RPM will be indicated).

NOTE: The 82.4 % value adjustment in the ACCELERATOR PEDAL parameter can be made with the engine stopped, as well.

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Index Electrical systems - 55 Cab engine controls - 525 Accelerator potentiometer - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Engine starting system - 201

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Contents Electrical systems - 55 Engine starting system - 201

FUNCTIONAL DATA Engine starting system Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

DIAGNOSTIC Engine starting system Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Electrical systems - Engine starting system

Engine starting system - Static description Operation and maintenance • The basic precondition for the starter motor to operate properly is an appropriate and fully charged battery.

• The starter motor is designed for short-term operation.

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

• Make sure feed cables have terminals perfectly tightened, insulation not broken.

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

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

• Confirm that the gear rim of the flywheel and pinion is not worn or torn. Lubricate with grease when inspecting.

• Check during engine repair or once every 2 years: Remove the starter motor from the machine. Check commutator, brushes, springs of the brushes, and switch contact surface Make sure the brushes contact the commutator with 3/4 of their surface and slide lightly. Make sure that contact surfaces of the switch contacts are not burnt and that they bear on each other with their full surface.

Check the idling – on the machine Test the starter motor in such a position where the pinion is not engaged with the gear rim even when shifted out.

With the starter motor circuit switched ON, the pinion must slip out and spin. An unloaded starter motor may operate for max. 10 s.

Starter motor troubleshooting Connect terminal 30 of the starter motor to a properly charged battery, connect an ammeter to the circuit with long effective range of wiring measurement. Start (supply current to terminal 50). Make sure the value of the current when idling does not exceed 120 A (peak during instant deflection is not taken into account). The starter motor must run quietly. Make sure the pinion shifts out and returns back to its home position smoothly. When the pinion is protruded, it should not spin right on the face of the cap ring. Slowing down of the starter motor after the sensor is disconnected from power supply may last only eight minutes. Check the pressure and condition of carbon springs. Make sure the carbon brushes contact commutator with at least 2/3 of their surface and are movable in the chambers. Confirm that the armature has perceptible axial clearance of max 1.3 mm (0.05 in). When turning the pinion slightly in the direction of the starter motor rotation, the free wheel must slip lightly. With sufficient experience, workshop appraisal to check with no load will be sufficient. However, we recommend the use of a test bench.

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Electrical systems - Engine starting system

SS12N458

1

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Electrical systems - Engine starting system

Engine starting system - Troubleshooting Problem Possible Cause Broken wire to switch’s 30 terminal The starter motor does not rotate when switched ON Broken wire to switch’s 50 terminal Faulty switch box Burnt contacts Broken winding for starter motor switch Switch is short-circuited Armature malfunction Starter motor runs in idle Shifting-out mechanism damaged Pinion is jamming on the shaft.

Faulty switch box Starter motor does not switch OFF —remains engaged.

Seized starter motor contacts Jammed pinion on the shaft

Correction Repair the wire.

Repair the wire.

Replace the switch box.

Replace the contacts and/or the entire cover.

Replace the starter motor switch.

Replace the starter motor switch.

Release, clean, and apply oil to the armature.

Replace the starter or repair.

Repair or align the shaft.

Replace the switch box.

Replace the contacts.

• Replace the pinion bearing.

• Remove the sharp edges on the shaft.

Starter motor does not shift out pinion to get engaged Pinion is milling the flywheel

Damaged flywheel rim

• Clean.

Repair the damaged rim and/or replace.

Broken shifting-out spring

Replace the spring.

Damaged pinion gearing Replace the pinion.

Discharged battery Recharge the battery.

Starter motor can be heard to engage pinion, but engine does not turn over Replace the wheel.

Damaged free wheel Burnt starter motor contacts Replace the contacts.

Recharge the battery.

Starter motor does not Insufficiently charged battery work reliably (low power) Dirty or loosened connections on the ca- Clean and tighten the connections. bles Repair or replace the battery.

Battery malfunctions Damaged carbon brushes on the starter Replace the carbon brushes. motor Dirty and burnt commutator • Clean with alcohol.

• Clean with alcohol.

• Mill out the insulation.

• Polish the commutator.

Loud starter motor operation

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

Broken and/or burnt carbon brush springs Replace the spring.

Armature short circuit Replace the armature.

Part of the exciting coils are disconnected Replace the relevant pair of coils.

Faulty starter motor switch Replace the switch box.

Broken stator excitation winding at the Solder the cable point. cable to the terminal for the starter motor switch Tighten the bolts.

Starter motor is loosened at the flange Loosened armature Mechanical defect

Repair the armature .

Repair the defect

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Electrical systems - Engine starting system

Problem Starter motor is hot

Possible Cause Broken cover Short circuit within the excitation circuit

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Correction Repair/replace the cover.

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

Index Electrical systems - 55 Engine starting system - 201 Engine starting system - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine starting system - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Electrical systems - 55 Alternator - 301

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Contents Electrical systems - 55 Alternator - 301

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

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

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

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Electrical systems - Alternator

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

There is a semiconductor voltage controller to maintain outlet voltage within a certain range at variable rpm, variable load and at variable ambient temperature.

Controlled voltage alternates on terminal B+.

Cooling is handled via a cooling air fan, where direction of rotation has been identified.

The alternator must always operate with the battery connected – positive battery pole connected to the B+ terminal.

Never disconnect a battery during operation.

Avoid any short circuits within the alternator circuit. When repairing wiring or performing welding, the alternator cables must be disconnected from the electrical system. When starting with an auxiliary external power supply, never disconnect the power supply before the battery is connected. Never run the alternator idle, i.e. with disconnected wire from B+ terminal and with L terminal connected.

Immediately replace the charging indicator light if defector. The alternator will not charge if the charging indicator light is not working. When washing the engine compartment, prevent water and dirt from penetrating into the alternator via the vents.

NOTE: During welding work on the machine you must disconnect the alternator – wires from B+ and L terminals – and electrical units or instruments with semiconductor elements. When repairing other electric equipment, disconnect the battery.

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

Preconditions for proper operation are as follows: • Sound wiring • Proper electric connections on alternator terminals, controller terminals, battery terminals • Sufficient drive belt tension - radial force affecting the alternator shaft via belt pull must be max. 800.0 N (179.8 lb) along pulley’s axis.

A faulty alternator or faulty controller may cause not only insufficient battery recharging but also battery overcharging.

During normal workshop inspection of the entire power- pack where no failure is expected, it will be enough to inspect control voltage or the reaction of the indicator light to increased rpm. With a voltmeter connected to the B+ terminal, the controlled voltage must move in the mean speed zone within 13 - 14 V.

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Electrical systems - Alternator

SS12N457

1

Voltage controller This involves an integrated voltage regulator. The alternator excitation circuit is connected between the DF and L terminals of the regulator. The regulator itself is connected to the carbon brush holder and the entire subassembly is secured to the alternator with 2 bolts. Its interconnection is made through three soldered circuits (B-, DF, D+) and a cable terminated with socket 6,3 to be slipped onto the alternator’s D+ connector. The regulator cannot be repaired.

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Electrical systems - Alternator

Alternator - Check Inspect alternator-regulator set using a test bench.

1.

Remove the regulator subassembly inclusive carbon brush holder from the alternator.

2.

Replace the subassembly with guaranteed sound regulator.

3.

Use a test bench to check controlled voltage.

Inspect alternator with no regulator – test bench.

1.

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

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

2.

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

3.

Move the alternator to approx. 1500 RPM.

4.

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

If excitation is not possible, the alternator is defective.

5.

Check alternator properties.

If no defect is found with the alternator, search for a regulator defect.

Poor contact between the alternator frame and vehicle frame or an improper battery ground connection could also be the cause of a fault.

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Electrical systems - Alternator

Alternator - Troubleshooting Problem Recharging indicator light ON while engine is running

Possible Cause Regulator fault

Rotor fault - short circuit of winding to frame Stator fault – short circuit to frame Diode fault in the block Loose soldered connections on diode cables or stator cables Recharging indicator light Defective indicator light does not go ON after ignition is turned ON. Bad connection on L terminal or on battery terminals Failed rotor Carbon brush is hanging in its holder

Correction Replace regulator

Replace rotor Replace stator Replace faulty diode Clean, and solder poor connections Replace the light

Clean the connections, and tighten

Replace rotor Release carbon brush, clean, or replace if required Dirty rotor rings Clean The alternator is Defective ground connection in charging Clean grounding points, and tighten overcharging the batteries system circuit Faulty regulator Replace the regulator Replace the auxiliary diode Auxiliary diode has failed

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

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Electrical systems - 55 Battery - 302

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Contents Electrical systems - 55 Battery - 302

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

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Electrical systems - Battery

Battery - Static description The battery is located in the box on the left-hand side of the frame’s front section.

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

A charging current lower than that indicated in the table is beneficial to the battery. The charging time lasts longer.

Let the filling holes be left free when charging. Once charging is completed, check the electrolyte level and density.

If required, refill and adjust density to 1.28 g/cm³. Screw in the plugs. After about 2 h of degassing, rinse the battery surface with water and wipe dry.

Charging table (example): Type L100

Rated capacity

Charging current

100 A·h

10 A

Indication of charge The battery is considered fully charged when all of its cells produce gas intensively and the electrolyte indicates 1.28 g/cm³ density in all cells. Each cell’s voltage reaches 2.5 - 2.7 V. The cumulative value for 6 cells is 14.4 V at the terminal pins.

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

The instantaneous state of charge is given by the values in the table below.

State of charge in % 100 70 50 20

Electrolyte density in g/cm³ 1.28 1.23 1.20 1.15

The data applies at an electrolyte temperature of 27 °C (80.6 °F). At a temperature lowered by 15.0 °C (59.0 °F), the measured density will be higher by 0.01g/cm³. When electrolytes are being replenished, the density measurements will stabilize after 10 - 30 min, depending on the magnitude of current upon intensive electrolyte gassing. Topping up with distilled water will be necessary before recharging or before any work up to a height of 5 - 10 mm (0.2 - 0.4 in) above the separators.

Handling in operation A charging assembly that operates properly will keep the battery close to a fully changed state. The controlled voltage level moves within 13 - 14 V limits.

With the voltage level adjusted like that, check the electrolyte level every 3 months. Check once a week during the summer season. Battery overcharging will show as high electrolyte loss. If charging is insufficient, electrolyte density will be reduced. The self-discharging current of the battery is about 1 % of its capacity each day.

Recharge the battery with 0.1 current of total capacity until there are signs that it is fully charged.

Keep the battery clean and properly secured. The securing equipment must not deform the battery block. Make sure the terminals on the battery are properly tightened.

Aerosol of electrolyte forms sulfates on the surface of terminals’ metal parts. Clean up these sulfates. Use a thin layer of Vaseline or oil to protect cleaned metal parts.

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Electrical systems - Battery

Recharge the batteries following 2 months of decommissioning.

DANGER 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 will result in death or serious injury.

D0116A

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

WARNING Hazardous chemicals!

Battery electrolyte contains sulfuric acid. Contact with skin and eyes could result in severe irritation and burns. Always wear splash-proof goggles and protective clothing (gloves and aprons). Wash hands after handling.

Failure to comply could result in death or serious injury.

W0006A

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Index Electrical systems - 55 Battery - 302 Battery - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Fuel tank system - 011

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Contents Electrical systems - 55 Fuel tank system - 011

SERVICE Fuel tank system Adjust – Fuel rate parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Configure – Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Fuel level sensor Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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Electrical systems - Fuel tank system

Fuel tank system - Adjust – Fuel rate parameter 1. Press the Menu button to move from the four-parameter display to the main menu. (2).

SS13G130

1

SS12N448

2

SS12N475

3

SS13A892

4

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

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

4. Move the cursor (1) to FUEL RATE. Confirm with Enter (2). Parameter No. 8 will be displayed.

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Electrical systems - Fuel tank system

5. Press the MENU pushbutton repeatedly till you have reached the four-parameter display.

SS13G130

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5

Electrical systems - Fuel tank system

Fuel tank system - Configure – Parameter 1. When in the four-parameter display, change the OIL PRES parameter to FUEL LEVEL (bottom left). Press the MENU button.

SS13G131

1

SS12N452

2

SS12N475

3

SS13G132

4

2. When you enter the main menu, move the left-hand (right-hand) cursor (1) to select SETUP 4 - UP DISPLAY. Confirm with Enter (2).

3. Move the left-hand cursor (1) to select CUSTOM SETUP. Confirm with Enter (2).

4. When in the four-parameter display, move the cursor (1) to select OIL PRESSURE. Confirm with Enter (2).

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Electrical systems - Fuel tank system

5. When in the parameter menu, move the cursor (1) to select FUEL LEVEL. Confirm with Enter (2) (2 will be displayed with the item). Press the MENU (3) button to move to the four-parameter screen.

SS13A048

5

SS13A888

6

6. FUEL LEVEL has been set (bottom left).

To store the data in the computer memory, turn OFF the battery master switch only after 30 s following multifunctional instrument setup completion.

ATTENTION: Failure to comply could result in minor or moderate injury.

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Electrical systems - Fuel tank system

Fuel tank system - Replace How to replace the fuel gauge 1. With the fuel gauge replaced, the following settings are not required to make, nevertheless the manufacturer recommends to carry out the settings with regard to fuel gauge tolerances.

Remove the alarm horn.

SS13A026

1

SS13A027

2

SS13A028

3

SS12C101

4

2. Unplug the connector of the alarm horn (A) and of the fuel gauge (B). Remove the defective fuel gauge.

3. Connect the wiring (C) to the new fuel gauge. Position the fuel gauge vertically, the fuel gauge float will fall down to the fuel gauge bottom (empty tank). While it is in this position, make the following settings of the multi-functional instrument.

4. With the ignition key turned ON, the four-parameter display will be shown. Press MENU to enter the main menu.

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Electrical systems - Fuel tank system

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

SS12N448

5

SS13A049

6

SS13A050

7

SS13A051

8

6. Move the cursor (1) to UTILITIES. Confirm with Enter (2).

7. Move the cursor (1) to ANALOG INPUT. Confirm with Enter (2).

8. Move the cursor (1) to FUEL LEVEL. Confirm with Enter (2).

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Electrical systems - Fuel tank system

9. Move the cursor (1) to SET EMPTY POINT. Confirm with Enter (2).

SS13A052

9

10. Turn the fuel gauge by 180 ° (full tank). Leave it in this position for the settings as follows.

SS13A029

10

SS13A893

11

SS13A053

12

11. Turn the fuel gauge by 180 ° (full tank). Leave it in this position for the settings as follows. Move the cursor (1) to SET FULL POINT. Confirm with Enter (2).

12. Move the cursor (1) to SET LOW FUEL LEVEL. Confirm with Enter (2).

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Electrical systems - Fuel tank system

13. Check or alter with the cursor the LOW FUEL value to 20 % min fuel level in the tank alarm. Confirm with Enter (2) – now it has been set.

Press the MENU (3) pushbutton step by step to move over to the four-parameter display.

SS13A054

13

SS13A888

14

ATTENTION: Turn OFF the master switch only after 30 s following multi-functional instrument setup to store the data in the computer memory.

The machine manufacturer does not permit to change set parameters aside from those mentioned above when multifunctional instrument or fuel gauge are replaced!

Failure to comply could result in minor or moderate injury.

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Fuel level sensor - Calibrate 1. Remove the alarm horn.

SS13A026

1

SS13A027

2

SS13A028

3

SS13G130

4

2. Unplug the connectors of the horn (A) and of the fuel gauge (B).

3. Remove the fuel gauge.

4. Take out the fuel gauge, and reconnect the wiring (C).

5. Position the fuel gauge vertically; the fuel gauge float will move to the fuel gauge bottom (representing an empty tank). Leave the fuel gauge in this position while programming the multifunction display.

6. Use the master switch to connect the battery.

7. Turn ON the key, and the four-parameter screen will be displayed.

8. Press MENU to enter the main menu.

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9. Move the cursor (1) to SETUP 1 - UP DISPLAY. 10. Confirm with Enter (2).

SS12N448

5

SS13A049

6

SS13A050

7

SS12N475

8

11. Move the cursor (1) to UTILITIES. 12. Confirm with Enter (2).

13. Move the cursor (1) to ANALOG INPUT. 14. Confirm with Enter (2).

15. Move the cursor (1) to CUSTOM SETUP. 16. Confirm with Enter (2).

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17. Move the cursor to (1) FUEL LEVEL..

18. Confirm with Enter (2).

SS13A051

9

19. Move the cursor to (1) SET EMPTY POINT. 20. Confirm with Enter (2).

SS13A052

10

SS13A029

11

SS13A893

12

21. Turn the fuel gauge by 180 °; the float will fall. (representing a full tank).

22. Move the cursor (1) to SET FULL POINT. 23. Confirm with Enter (2).

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24. Move the cursor (1) SET LOW FUEL LEVEL. 25. Confirm with Enter (2).

SS13A053

13

SS13A054

14

SS12N448

15

SS12N475

16

26. Check or use the cursor (1) to change the LOW FUEL value to 20 %. (This value represents the minimum fuel level in tank alarm.)

27. Confirm with Enter (2).

28. The system is now programmed. Press the Menu button (3) three times to enter the main menu.

29. Move the cursor (1) to SETUP 1 - UP DISPLAY. 30. Confirm with Enter (2).

31. Move the cursor (1) to CUSTOM SETUP. 32. Confirm with Enter (2).

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33. Move the cursor (1) to FUEL LEVEL. 34. Confirm with Enter (2) (parameter number 7 will be displayed).

35. Press the MENU button (3) step by step to the fourparameter display.

SS13A890

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17

Index Electrical systems - 55 Fuel tank system - 011 Fuel level sensor - Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Fuel tank system - Adjust – Fuel rate parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Fuel tank system - Configure – Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Fuel tank system - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Contents Electrical systems - 55 Electronic modules - 640

FUNCTIONAL DATA Controller Area Network (CAN) data bus Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Controller Area Network (CAN) data bus - Dynamic description Introduction CAN is an acronym for Controller Area Network. The bus connects controllers on a machine, and allows information to be shared between the controllers. CAN was first developed by Bosch and Intel in 1984, and has been in use in the automotive and truck industry since the late 1980‘s. Applications of CAN follow guidelines that are established in SAE J1939.

Glossary of terms Bus CAN CAN HI CAN LO Controller

Terminator

The network, e.g. the wires, connectors, and terminators between the controllers.

Controller Area Network. Generally refers to all parts of the system -the controllers, wires, and terminators.

A high priority, message carrying wire on the CAN bus.

A low priority, message carrying wire on the CAN bus.

Components that are connected by the bus and share information. May also be referred to as processors, control modules, units, or modules.

An electrical resistor or circuit placed at either end of the bus. They may be passive or active type. They may be a separate component or part of a controller. Terminators prevent a message from rebounding along the bus, clear the bus for the next message, and allow clear messages to travel the bus.

Purpose In the past, if a speed sensor‘s information was needed by a tachometer, an engine controller, and a transmission, the three devices would need to be wired to the speed sensor. The complexity of wiring can be greatly reduced through the use of a CAN bus system. A controller sends the speed sensor data onto the bus, and the other controllers on the bus can read the data. Any controller on the bus that does not care about the data will ignores the message.

A CAN bus system also offers improved diagnostics with the use of the Electronic Service Tool (EST). The controllers can detect errors, and fault codes can be displayed to the operator and technician. Onboard diagnostics may provide the ability to test and monitor circuits during operation, aiding in troubleshooting.

The advantage of a CAN bus system are: 1. A decrease in the number of wires and overall length of the wiring harness.

2. Information is received by one controller which shares the information with the other controllers on the bus.

3. Less wiring and fewer connectors improve reliability and durability.

4. Improved diagnostics with the EST.

Operation When the CAN bus is initially powered up (keyswitch on), each controller on the bus sends a message announcing its existence and looks for messages from other controllers on the bus. After this initial message, each controller sends data messages as necessary. The frequency of these messages is based on software programming, with important messages broadcast more frequently than low priority messages.

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RAIL13TR03931FA

1

If a controller has not sent any messages within five seconds, it will broadcast a message that announcing its existence. This is done in order to monitor each controller’s status on the bus. If a certain controller has not transmitted any messages for more than five seconds, then the other controllers on the bus will generate an alarm message indicating that a controller is offline.

NOTE: This offline status condition may vary from one machine type to another. Some machines may need to be configured to know that a specific controller is on the bus. However, this process of existence messages generally holds true.

In a CAN system, controllers are positioned near the majority of their sensors and switches. For example, the Engine Control Unit (ECU) is located in the engine compartment near the engine sensors. This results in less wiring, fewer connections, and a reduction in the number of error sources.

The voltage signal from sensors and switches are processed by a controller, which converts the signal to a data message. The data message is sent to the bus by the controller. Every controller that is connected to the bus can read and process the data message as required. Each controller knows which information it needs based on the software that is programmed into it.

The terminators absorb the voltage signals at either end of the bus. They are constantly trying to maintain of voltage of 2.5 V on the bus. Terminators prevent a signal from rebounding along the bus, clear the bus for the next signal, and allow clear messages to travel the bus.

Terminators Terminators help eliminate the reflections that can occur when a message reaches the end of the bus. These reflections can cause interference (noise) on a CAN bus, creating communication problems between the controllers.

A good way to explain how terminators work is to think about dropping a stone into a pond. After the stone hits the water, the waves travel to the edges of the pond and then rebound to the center. Terminators absorb the waves at the edges and deny the rebound of the waves to the source.

Passive terminator or active terminator 1. Passive terminators are usually 120 Ω resistors placed at either end of the bus. Passive terminators are typically used with a two wire CAN system. These resistors are connected between the CAN HI and CAN LO wires. Passive termination is popular because it is a fraction of the cost of active terminators. Passive terminators act as snubbers to kill reflections and work efficiently on systems with lower bus loading (low CAN bus traffic).

2. Active terminators are voltage regulators, and require a external voltage supply to operate. Active terminators are typically used with a four wire CAN system. Active terminators produce 2.5 V on the CAN HI and CAN LO wires to maintain the standard CAN wire voltage. This means they bring the wires to neutral. Active terminators are very efficient, and are typically used on systems with high bus loading (high traffic).

Troubleshooting The CAN system is capable of diagnosing itself and generating an alarm messages to the operator when problems are present. The vehicle may continue to function when an alarm messages appears, but the systems related to that controller may no longer function. When troubleshooting a vehicle with suspected CAN system failure, it is important to determine if the problem is related to one or more controllers or if the bus is at fault.

CAN system problems will generally fall into two categories: 47703681 09/09/2015

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1. Problems with individual controllers that affect certain functions, such as transmission or engine operation.

2. Problems with the bus. (The wires between the controllers.)

Some questions to answer are: 1. What functions are affected?

2. Are the affected functions related to a specific controller or several different controllers?

3. Are there any error codes or alarm messages active?

4. Are the error codes and/or alarm messages related to a specific controller or are they indicating an fault with the entire system?

If only one or two controllers are affected on the vehicle, then those controllers should be tested for faults before suspecting a CAN bus failure.

There are two general conditions that may cause an individual controller to go offline.

1. Loss of power or ground to the controller.

2. Controller related faults, such as a CAN controller failure, poor or failed CAN connector, or message errors.

Loss of power or ground The controllers are not powered through the CAN bus wires. Each controller requires a power supply and ground supply. If power or ground is lost, the controller will deactivate and will not be active on the bus. In addition, most controllers require a minimal voltage level to activate, so weak batteries, a faulty charging system, or poor connections may prevent controllers from properly activating.

Controller faults Whenever a controller transmits or receives a fault message, it keeps a record of that error. After its error history fills, the controller assumes that it is faulty, and will stop transmitting on the bus. We describe this situation as a controller that has gone “bus off,” which may cause an alarm message to be displayed. This error history is erased and reset at zero when the controller is deactivated.

There are several CAN related faults that may cause a controller to go offline: 1. External problems like bad or open connections to the CAN HI wires and CAN LO wires as a result of damaged wiring. Inspect the wiring for damage, and use a multimeter to check for continuity to the wires.

2. Internal problems like a failure of the controller itself. If the controller is activating but never communicates on the bus, the controller may have failed. If the controller is activating and is initially online but goes offline after a short period of operation, it may be in a bus off state.

Faulty messages may result from: 1. Failed terminators (signal reflection occurring) on the CAN bus. Test the terminators for proper operation.

2. Bad connections (e.g. loose pins, corroded terminals, damaged wires) between the controller and the bus.

3. A problem with the controller.

If several controllers are offline or the vehicle will not start, there may be a problem with the actual CAN bus. The wires may be shorted to 12 V, shorted to ground, open, or shorted together. Any of these problems can affect the entire CAN bus.

Testing the CAN bus There are several things to consider when testing CAN systems. The primary concern should be to confirm the integrity of the CAN bus circuit, after which you should check for shorts to battery voltage or to chassis ground.

You can easily test the CAN bus (CAN HI and CAN LO) for open circuits by conducting a circuit continuity check at the vehicle’s diagnostic connector. However, for vehicles that use active terminators, it is necessary to unplug those terminators, and replace them with jumper wires between the CAN HI wires and CAN LO wires.

For our machine, we deactivate all systems and use a multimeter (1) to check the resistance between pins C and D of our vehicle’s diagnostic connector (2).

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NOTE: The CAN circuit that is being tested must be connected to the diagnostic connector.

RAIL13TR03932FA

2

The resistance across the CAN circuit between CAN HI (3) and CAN LO (4) should be approximately 54 - 66 Ω. A reading of 54 - 66 Ω indicates that the passive terminators are good and confirms the integrity of the CAN bus circuit.

A reading of 70 - 150 Ω generally indicates that either a passive terminator has failed or there is an open circuit in either the CAN HI wires or CAN LO wires. You must perform additional testing to isolate the source of the fault.

A reading of infinite resistance indicate that either both passive terminators have failed or there is an open circuit in both CAN HI wires and CAN LO wires.

A reading of 53 Ω or less indicates poor connections in the circuit.

A reading of very low resistance indicates that the CAN HI wires and CAN LO wires are shorted together. Additional testing must be completed to determine the location of the short.

Testing the terminators If a passive terminator is suspected as a source of a CAN bus problem, disconnect the passive terminator from the CAN bus and test the resistance of passive terminators with a multimeter. Passive terminators should have a resistance of approximately 120 Ω.

NOTE: Some terminators may be an internal part of a controller. Disconnect the controller from the harness before testing.

Testing the CAN bus voltage A CAN circuit can be tested by testing the voltage of the CAN HI wires and CAN LO wires while the system is activated.

This test may provide some indication if the CAN circuit is shorted to high voltage or to ground, but is not conclusive of CAN system operation. If a fault is suspected, you must complete additional testing to locate the type and source of the fault.

Use a multimeter to check the voltage between either the CAN HI wires or CAN LO wire and chassis ground.

1. The CAN HI circuit should read approximately 2.5 - 3.5 V. 2. The CAN LO circuit should read approximately 1.5 - 2.5 V.

Testing the CAN bus for shorts to battery voltage If there is a short from a 12 V source to CAN HI or CAN LO, the controllers cannot send information on the CAN system.

With the keyswitch on, use a multimeter to check the voltage from the circuit to ground. This needs to be carried out for both the CAN HI and CAN LO wires. If data line voltage is at battery voltage, data can no longer be transmitted. If such an error is found on a data line, localize the error by opening the circuit at intermediate connectors and repeating this test.

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Testing the CAN bus for shorts between the wires If there is a short between the CAN HI wires and CAN LO wires, the controllers cannot send information on the CAN bus.

Turn the keyswitch off. Disconnect the terminators from the CAN HI wires and CAN LO wires, so the wires are open.

Use a multimeter to check for continuity between the CAN HI wires and CAN LO wires. If there is continuity, the two wires are shorted together. If such an error is found, localize the error by opening the circuit at intermediate connectors and repeating this test.

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Index Electrical systems - 55 Electronic modules - 640 Controller Area Network (CAN) data bus - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Contents Electrical systems - 55 Cab controls - 512

SERVICE Instrument cluster Configure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Instrument cluster - Configure Menus have pages with other items.

1. Use the navigation buttons to select highlighted items.

Operate the buttons with a light touch.

SS12C097

1

SS12C098

2

SS12C099

3

2. Use Enter (1) to open the highlighted item. Press the Menu button (2) to access the main menu.

Display four items 1. Use the navigation buttons to select the “Go To 4 up display” option.

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2. Press the Enter button to access the “Go To 4 up display” screen.

SS12C100

4

SS12C101

5

SS13G113

6

3. Four-parameter display will be displayed. Press the Menu button to display main menu.

NOTE: Four-parameter display is the default screen; turn On the Ignition switch to display this screen.

4. By pressing the left or right arrow, the four additional parameters are displayed.

NOTE: By pressing the left/right button, it’s possible to switch between the two main four-parameter views.

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Display one item 1. Use the navigation buttons to navigate to “Go To 4 up display” menu and press Enter button to access the “Go To 4 up display” screen. In this screen the parameters are displayed one by one.

2. Use the cursor (1) to select one of the following preset parameters: • Engine operating hours • Engine speed • Electrical system voltage • Engine load in % at actual engine speed • Coolant temperature

SS12C302

7

SS12C303

8

SS12C305

9

• Engine oil pressure • Fuel level • Instantaneous consumption • Accelerator pedal position 3. Press the Menu (2) button to display the highlighted parameter..

NOTE: When the electrical system voltage is selected and if the engine is at rest, the battery voltage is indicated. If the engine is running, the roller’s electrical system voltage is indicated.

Languages Use the “Languages” option to set the display language.

1. To select a language, navigate to “Languages” option and press the Enter button.

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2. From the list of available languages, select a language using the navigation buttons. Press Enter to set the highlighted language as the display language.

SS12C106

10

SS12C307

11

SS12C308

12

3. Press Menu to return to the main menu.

Engine diagnostics Use the “Stored codes” option to display the list of fault codes registered by the Engine Control Unit (ECU).

1. To use this option, navigate to the “Stored codes” option and press the Enter button.

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2. The screen displays the fault code and description.

Press the Enter button to display the fault code.

SS12C309

13

SS12C112

14

SS12C303

15

3. When there are more than one fault code is registered, the word “More” appears below the current fault code, use the cursor to display the other faults codes.

Press the Menu button to return to the main menu.

Engine parameters 1. Use the navigation buttons to navigate to the “Engine Conf” menu. When this menu is selected the preset engine parameters are displayed in the screen.

NOTICE: Though the list of preset parameters can be modified by using the “Custom setup” option, the roller manufacturer does not recommend the modification to the list of parameters. The set parameters are the best possible parameters for checking engine functionality.

2. Use the “Setup 1 up display” option to show various parameter display options.

Use the “Custom setup” option (not recommended) to select the number of parameters displayed and to set the sequence in which parameters will be displayed.

The following parameters have been set by the machine manufacturer by default.

• Engine speed (RPM) • Coolant temperature • Engine oil pressure • Engine load in percentage at actual engine speed • Electrical system voltage • Engine operating hours • Fuel level • Current fuel consumption rate • Accelerator pedal position

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3. Use the “Automatic scanner” option to display the preset parameters automatically one by one at a set time interval.

SS12C303

16

SS12C311

17

SS12C312

18

SS12C314

19

Units of measurements 1. In the main menu, use the “Select units” option to select the measurement units for displayed parameters.

2. Use the cursor (2) to set Imperia (English) and the indicated variables will be displayed in Pounds per Square Inch (PSI) (pressure) and °F (Fahrenheit temperature).

When “Metric KPa” or Metric Bar” is set, the parameters are displayed in SI units, i.e. kPa/bar and °C (Celsius temperature). Press Enter (1) to confirm selected variables. Press Menu (3) to return to the main menu.

Display brightness and contrast 1. In the main menu, use the “Adjust backlight” to adjust intensity of display backlight.

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2. Use the cursor to adjust backlight intensity.

SS12C315

20

SS12C316

21

SS12C097

22

SS12C319

23

3. Press Menu to return to the main menu.

4. In the main menu, use the “Adjust contrast” to adjust the display contrast.

5. Press cursor (arrows) to adjust contrast.

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6. Press Menu to return to the main menu.

SS12C320

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24

Index Electrical systems - 55 Cab controls - 512 Instrument cluster - Configure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

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

SERVICE Instrument cluster Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

DIAGNOSTIC Instrument cluster Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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

Fault code list Fault code 115

Lamp color Red

122

Amber

123

Amber

125

Amber

131

Red

132

Red

133

Red

134

Red

135

Amber

141

Amber

143

Amber

144

Amber

145

Amber

146

Amber

147

Red

148

Red

151

Red

153

Amber

154

Amber

155

Red

187

Amber

193

Amber

194

Amber

195

Amber

Description Definition System diagnostic code # 2 Engine speed/position sensor circuit lost both of two signals from the magnetic pickup sensor - data erratic, intermittent, or incorrect Boost pressure Intake manifold pressure sensor circuit - voltage above normal, or shorted to high source Boost pressure Intake manifold pressure sensor circuit - voltage below normal, or shorted to low source Engine intake manifold #1 Intake manifold 1 pressure - data valid but below pressure normal operating range - moderately severe level Accelerator pedal position Accelerator pedal or lever position sensor circuit voltage above normal, or shorted to high source Accelerator pedal position Accelerator pedal or lever position sensor circuit voltage below normal, or shorted to low source Remote accelerator Remote accelerator pedal or lever position sensor circuit - voltage above normal, or shorted to high source Remote accelerator Remote accelerator pedal or lever position sensor circuit - voltage below normal, or shorted to low source Engine oil pressure Oil pressure sensor circuit - voltage above normal, or shorted to high source Engine oil pressure Oil pressure sensor circuit - voltage below normal, or shorted to low source Engine oil pressure Oil pressure low - data valid but below normal operational range - moderately severe level Engine coolant temperature Coolant temperature sensor circuit - voltage above normal, or shorted to high source Engine coolant temperature Coolant temperature sensor circuit - voltage below normal, or shorted to low source Engine coolant temperature Coolant temperature high - data valid but above normal operational range - moderately severe level Accelerator pedal position Accelerator pedal or lever position sensor circuit abnormal frequency, pulse width, or period Accelerator pedal position accelerator pedal or lever position sensor circuit abnormal frequency, pulse width, or period Engine coolant temperature Coolant temperature low - data valid but above normal operational range - most severe level Intake manifold #1 Intake manifold air temperature sensor circuit temperature Voltage Above Normal, or Shorted to High Source Intake manifold #1 Intake manifold air temperature sensor circuit temperature voltage below normal, or shorted to low source Intake manifold #1 Intake manifold air temperature high – data valid temperature but above normal operational range - most severe 5 volts DC supply Sensor supply voltage #2 circuit - voltage below normal, or shorted to low source Cruise control Cruise control (resistive) signal circuit - voltage above normal, or shorted to high source Cruise control Cruise control (resistive) signal circuit - voltage below normal, or shorted to low source Coolant level Coolant level sensor circuit - voltage above normal, or shorted to high source 47703681 09/09/2015

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196

Amber

Coolant level

197

Amber

Coolant level

221

Amber

Barometric pressure

222

Amber

Barometric pressure

227

Amber

5 volts DC supply

234

Red

Engine speed

235

Red

Coolant level

237

Amber

External speed input

238

Amber

System diagnostic code # 1

239

Amber

System diagnostic code #2

241

Amber

Wheel-based vehicle speed

242

Amber

Wheel-based vehicle speed

244

Amber

Red stop lamp

245

Amber

271

Amber

272

Amber

281

Amber

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

285

Amber

SAE J1939 datalink

286

Amber

SAE J1939 datalink

287

Red

Accelerator pedal position

288

Red

Remote accelerator

292

Red

Auxiliary temperature 1

293

Amber

OEM temperature

294

Amber

OEM temperature

295

Amber

Barometric pressure

296

Red

Auxiliary pressure

297

Amber

Auxiliary pressure

298

Amber

Auxiliary pressure

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

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Electrical systems - Warning indicators, alarms, and instruments

322 323 324 325 331 332 343 349

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

489

497

Amber

Injector cylinder #01

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

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Electrical systems - Warning indicators, alarms, and instruments

515 516 523 527 528 529 553

555 556 559

584 595 599 649 687 689 691

697 698 731

769 771 778 779 951 952 953 1117

Amber

Not available

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

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Electrical systems - Warning indicators, alarms, and instruments

1239

Amber

Accelerator pedal position

1241

Amber

Not available

1242

Red

Accelerator pedal position

1381

Amber/ Blinking Not available

1663

Amber

Not available

1664

Amber

Not available

1665

Amber

Not available

1666

Amber

Not available

1667

Amber

Not available

1674

Amber

Not available

1675

Amber

Not available

1676

Amber

Not available

1691

Amber

Not available

1695

Amber

Not available

1696

Amber

Not available

1843

Amber

Not available

1844

Amber

Not available

1847 1852

Red Amber

Not available Water in fuel indicator

1866

Amber

Not available

1876

Amber

Not available

1877

Amber

Not available

1878

Amber

Not available

1879

Amber

Not available

1881

Amber

Not available

1883

Amber

Not available

1896 1911

Amber Amber

Not available Injector metering rail

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

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Electrical systems - Warning indicators, alarms, and instruments

1921

1922

1938

1939 1941 1942 1943 1962

1968

1972

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

2274

2288

Amber

Not available

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

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Electrical systems - Warning indicators, alarms, and instruments

2292

Amber

Fuel inlet meter device

2293

Amber

Fuel inlet meter device

2311 2321

Amber None

Fuel control valve #1 Engine speed

2322

None

Engine speed sensor #2

2346

None

System diagnostic code #1

2349

Amber

Not available

2351

Amber

Not available

2353

Not available

Not available

2357

Amber

Not Available

2363

Amber

2365

Amber

Engine compression brake output # 2 Engine brake output # 3

2367

Amber

2368

Amber

Engine compression brake output # 2 Engine brake output # 3

2372

Not Available

Not Available

2373

Amber

Exhaust gas pressure

2374

Amber

Exhaust gas pressure

2375

Amber

Exhaust Gas Recirculation (EGR) temperature

2376

Amber

Exhaust Gas Recirculation (EGR) temperature

2377

Amber

2387

Amber

Fan clutch output device driver Not available

2448

Amber/ Blinking Coolant level

2449 2468

Red Not available

Not available Not available

2554

Amber

Not Available

2555

Amber

Inlet air heater driver #1

2556

Amber

Inlet air heater driver #1

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

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Electrical systems - Warning indicators, alarms, and instruments

2557

Amber

2558

Amber

2571

Amber

2572

Amber

2634

Red

2635 2636 2637

Red Red None

2638

None

2639

None

2646 2659 2699

Amber None Amber

2728

None

2742

None

2743

Amber

2754

Amber

2764

Amber

2765 2774

None Amber

2777

None

2778

Amber

2789

Amber

2961

None

2962

Amber

2973

Amber

2998 3133

Amber Amber

Not available

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

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Electrical systems - Warning indicators, alarms, and instruments

3134

Amber

Not available

3135

Amber

Not available

3136

Amber

Not available

3137

Amber

Not available

3139

Amber

Not available

3141

Amber

Not available

3168

Amber

Not available

3186

Amber

Not available

3213

Amber

Not available

3222

Amber

Not available

3251

Red

Not available

3253

Red

Not available

3254

Amber

Not available

3295

Amber

Not available

3296

Amber

Not available

3311

Red

3312

Red

3313

Amber

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

3314

Amber

Not available

3315

Amber

Not available

3316

Amber

Not available

3317

Amber

Not available

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

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Electrical systems - Warning indicators, alarms, and instruments

3318

Amber

Not available

3325

Amber

Not available

3326

Red

Not available

3328

Amber

Not available

3329

Amber

Message selection control

3331

Amber

Not available

3369

Amber

Not available

3371

Amber

Not available

3372

Amber

Not available

3373

Amber

Not available

3377

Amber

Not available

3712

Red

Not available

3727

NA

Not available

3737

NA

Not available

3918

Amber

Not available

3921

Amber

Not available

3922

Amber

Not available

3923

Amber

Not available

3924 3925

Amber Amber

Not available Not available

3927

Amber

Not available

3928

Amber

Not available

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

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Electrical systems - Warning indicators, alarms, and instruments

Instrument cluster - Replace 1. Remove the screws along the instrument board perimeter.

SS13A030

1

SS13A025

2

2. Fold up the instrument board, unplug the connector from the socket (A), and remove the fixing nut (B). Connect the new instrument and reassemble the instrument board.

Before you remove it, disconnect the battery via master switch.

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Electrical systems - Warning indicators, alarms, and instruments

Instrument cluster - Adjust With the multi-functional display instrument replaced, the following parameters must be adjusted: –) Fuel level in tank –) Fuel rate –) Change four–parameter setting display –) Accelerator pedal position

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Electrical systems - Warning indicators, alarms, and instruments

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

“TIMEOUT ECU NOT RESPONDING” is displayed

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

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

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

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

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

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

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

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

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

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

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1. Check the functionality of the fuel level sensor.

2. Check the circuit of the fuel level sensor.

Select a parameter to be displayed in the quadrant.

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

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

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Electrical systems - 55 FAULT CODES - DTC

PT240

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Contents Electrical systems - 55 FAULT CODES - DTC

DIAGNOSTIC 115-3928-Fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - FAULT CODES

115-3928-Fault codes NOTE: All fault codes should be diagnosed by an authorized engine dealer. Please contact your local engine dealer for assistance. Please see Instrument cluster - Fault code index (55.408) for a list of this machine’s fault codes.

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Index Electrical systems - 55 FAULT CODES - DTC 115-3928-Fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

PRINTED IN U.S.A. © 2015 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

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

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

47703681 09/09/2015 EN

SERVICE MANUAL Tools PT240

47703681 09/09/2015

89

Contents Tools - 89

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

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89

Tools - 89 Water kit - 165

PT240

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Contents Tools - 89 Water kit - 165

SERVICE Water kit Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Tools - Water kit

Water kit - Remove 1. Drain water from the water tank.

SS12N074

1

SS12N075

2

SS12N076

3

SS12N077

4

2. Remove the water tank fastening straps.

3. Lift the cover and remove the hose leading to the sprinkling filter.

4.

WARNING Falling object hazard!

DO NOT go underneath a hanging load. Make sure the area is clear of all bystanders.

Failure to comply could result in death or serious injury.

W1129A

Suspend the water tank and move it aside.

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Index Tools - 89 Water kit - 165 Water kit - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

PRINTED IN U.S.A. © 2015 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

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

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

47703681 09/09/2015 EN

SERVICE MANUAL Platform, cab, bodywork, and decals PT240

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90

Contents Platform, cab, bodywork, and decals - 90

[90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 [90.114] Operator protections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2 [90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3

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90

Platform, cab, bodywork, and decals - 90 Cab - 150

PT240

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Contents Platform, cab, bodywork, and decals - 90 Cab - 150

SERVICE Cab Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Cab front mounts Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Platform, cab, bodywork, and decals - Cab

Cab - Remove 1. Remove the bolts used to secure the cab to the machine frame (along the cab perimeter).

NOTE: The assembly of the platform with ROPS is the same as the assembly of the cab.

SS12N355

1

SS12N356

2

SS12N357

3

SS12N358

4

2. Remove the rear panel for air distribution.

3. Disconnect the cab wiring.

4.

WARNING Falling object hazard!

DO NOT go underneath a hanging load. Make sure the area is clear of all bystanders.

Failure to comply could result in death or serious injury.

W1129A

Suspend the cab and move it aside.

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Platform, cab, bodywork, and decals - Cab

5. Remove the bolts securing the left seat.

NOTE: Remove the bolt inside the box (underneath the seat). This bolt secures the box to the machine frame.

SS12N723

5

SS12N359

6

SS12N724

7

SS12N725

8

6. Remove the left seat.

7. Remove the floor covers (A) (B) to access the joint shaft.

8. Remove the cover (C). Open the maintenance cover (D) and secure it in the open position.

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Platform, cab, bodywork, and decals - Cab

9. Remove the exhaust flange clamp.

SS12N360

9

10. Remove the holder and the muffler.

SS12N361

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10

Platform, cab, bodywork, and decals - Cab

Cab front mounts - Remove 1. Let the air out via the blow-off valve on the air tank.

SS12D625

1

SS12N726

2

SS12N362

3

SS12N363

4

2. Let the air out via the drain valve from the tires underneath the instrument board.

3. Remove the clamps – left-hand side.

4. Remove the clamps – right-hand side.

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Platform, cab, bodywork, and decals - Cab

5. Remove the hoses – right-hand side.

SS12N364

5

SS12N365

6

SS12N366

7

SS12N367

8

6. Remove the hoses – left-hand side.

NOTE: Mark the hose ends.

7. Remove the instrument board.

8. Fold it up.

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Platform, cab, bodywork, and decals - Cab

9. Remove the cable tie.

SS12N368

9

10. Remove the frame with grommets.

SS12N369

10

SS12N370

11

SS12N371

12

11. Unplug the connectors underneath the instrument board (with the panel removed).

12. Remove the brake fluid tank.

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Platform, cab, bodywork, and decals - Cab

13. Disconnect the wiring of the left-hand accelerator pedal position sensor.

SS12N372

13

SS12N373

14

SS12N374

15

SS12N375

16

14. Remove the bolts securing the panel to the machine frame.

15. Raise the panel and remove the two hoses for the right-hand side brake pedal.

16. Remove the two hoses for the left-hand side brake pedal and the plastic hose for air distribution.

Suspend the front panel from a lifting device with sufficient load capacity and move it aside.

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Platform, cab, bodywork, and decals - Cab

17. Remove four hoses.

SS12N757

17

SS12N758

18

SS12N236

19

18. Remove the hose and cut off the retaining straps.

19. Remove the air distribution hoses. Move the panel aside off of the machine.

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Index Platform, cab, bodywork, and decals - 90 Cab - 150 Cab - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Cab front mounts - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Platform, cab, bodywork, and decals - 90 Operator protections - 114

PT240

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Contents Platform, cab, bodywork, and decals - 90 Operator protections - 114

SERVICE Operator protections Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Platform, cab, bodywork, and decals - Operator protections

Operator protections - Remove 1. Install the M16 lifting lugs onto the Roll Over Protection Structure (ROPS), and hang the ROPS on an adequate lifting device.

NOTE: The lifting lugs are considered machine equipment.

SS12N078

1

SS12N079

2

SS12N350

3

2. Remove the ROPS bolts.

3.

WARNING Falling object hazard!

DO NOT go underneath a hanging load. Make sure the area is clear of all bystanders.

Failure to comply could result in death or serious injury.

W1129A

Move the ROPS aside.

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Platform, cab, bodywork, and decals - Operator protections

Operator protections - Install 1.

WARNING Falling object hazard!

DO NOT go underneath a hanging load. Make sure the area is clear of all bystanders.

Failure to comply could result in death or serious injury.

W1129A

Carefully lower the Roll Over Protection Structure (ROPS) into position.

SS12N350

1

SS12N079

2

2. Install the ROPS bolts, and torque the bolts to 550 N·m (405.7 lb ft).

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Index Platform, cab, bodywork, and decals - 90 Operator protections - 114 Operator protections - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Operator protections - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Platform, cab, bodywork, and decals - 90 Engine hood and panels - 100

PT240

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Contents Platform, cab, bodywork, and decals - 90 Engine hood and panels - 100

SERVICE Engine hood and panels Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Platform, cab, bodywork, and decals - Engine hood and panels

Engine hood and panels - Remove 1. Remove the front cover. Use a lifting device.

SS12E074

1

SS12N351

2

SS12N352

3

SS12N353

4

2. Lift the hood and secure it in the raised position.

Remove the hood strut.

3. Lower the hood.

Remove the cover along both sides.

4. Remove the bolts from the hood brackets.

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Platform, cab, bodywork, and decals - Engine hood and panels

5.

WARNING Falling object hazard!

DO NOT go underneath a hanging load. Make sure the area is clear of all bystanders.

Failure to comply could result in death or serious injury.

W1129A

Move the hood aside. Use a lifting device.

SS12N354

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5

Index Platform, cab, bodywork, and decals - 90 Engine hood and panels - 100 Engine hood and panels - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

PRINTED IN U.S.A. © 2015 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

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

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

47703681 09/09/2015 EN

47703681 09/09/2015 EN

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

PRINTED IN U.S.A. © 2015 CNH Industrial America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

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

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

47703681 09/09/2015 EN