Case SV208 SV210 SV212 SV216 Tier 3 Vibratory Roller Service Manual PN 47688018 - PDF DOWNLOAD

SV208 SV210 SV212 SV216 Tier 3 Vibratory Roller

SERVICE MANUAL

Part number 47688018 2nd edition English June 2014 Replaces part number 87480985NA

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

Power coupling........................................................................... 19 [19.110] Flywheel damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1

Hydrostatic drive......................................................................... 29 [29.218] Pump and motor components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.1 [29.202] Hydrostatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.2

Brakes and controls .................................................................... 33 [33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1

Hydraulic systems....................................................................... 35 [35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.995] Compaction/vibration hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3

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

Steering..................................................................................... 41 [41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1

Wheels ...................................................................................... 44 [44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1 [44.160] Compaction drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2

Cab climate control ..................................................................... 50 [50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1

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Electrical systems ....................................................................... 55 [55.011] Fuel tank system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.036] Hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7

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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 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Torque - Standard torque data for hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Basic instructions - Shop and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Hydraulic contamination – Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 General specification - Machine control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Part identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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

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

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INTRODUCTION

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

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

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

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

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

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

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

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

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

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

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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 are vital factors of agriculture and life in general. When legislation does not yet rule the treatment of some of the substances required by advanced technology, sound judgment should govern the use and disposal of products of a chemical and petrochemical nature.

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

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

• Agricultural consultants will, in many cases, be able to help you as well.

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

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

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

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

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

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

• Do not open the air-conditioning system yourself. It contains gases that should not be released into the atmosphere.

Your CASE CONSTRUCTION dealer or air conditioning specialist has a special extractor for this purpose and will have to recharge the system properly.

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

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

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

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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

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)

8 10 10 12

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INTRODUCTION

Size wrench

Thread size

36

30x2

41 46

36x2

50

42x2

30

45x2

35

52x2

38 42

50

Hose 20 22 25 28

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)

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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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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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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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

Hydraulic contamination – Contamination Contamination in the hydraulic system is a major cause of the malfunction of hydraulic components. Contamination is any foreign material in the hydraulic oil. Contamination can enter the hydraulic system in several ways.

1. When you drain the oil or disconnect any line.

2. When you disassemble a component.

3. From normal wear of the hydraulic components.

4. From damaged or worn seals.

5. From a damaged component in the hydraulic system.

All hydraulic systems operate with some contamination. The design of the components in this hydraulic system permits efficient operation with a small amount of contamination. An increase in this amount of contamination can cause problems in the hydraulic system. The following list includes some of these problems.

1. Cylinder rod seals leak.

2. Control valve spools do not return to neutral.

3. Movement of control valve spools is difficult.

4. Hydraulic oil becomes too hot.

5. Pump gears, housing, and other parts wear rapidly.

6. Relief valves or check valves held open by dirt.

7. Quick failure of components that have been repaired.

8. Cycle times are slow; machine does not have enough power.

If your machine has any of these problems, check the hydraulic oil for contamination. See types of contamination below. If you find contamination, use the Portable Filter to clean the hydraulic system.

NOTE: There are two types of contamination, microscopic and visible.

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

These particles are too small to see or feel. Microscopic contamination can be found by identification of the following problems or by testing in a laboratory. Examples of the problems: 1. Cylinder rod seal leak.

2. Control valve spools do not return to NEUTRAL. 3. The hydraulic system has a high operating temperature.

Visible contamination is foreign material that can be found by sight, touch, or odor. Visible contamination can cause a sudden failure of components. Examples of visible contamination: 1. Particles of metal or dirt in the oil.

2. Air in the oil.

3. The oil is dark and thick.

4. The oil has an odor of burned oil.

5. Water in the oil.

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INTRODUCTION

General specification - Machine control panel Dashboard and control panel

SS13G111

1

Dashboard and control panel identification Item 1 8 9 10

Designation Ignition switch Engine speed selector Power View display Hydraulic oil temperature gauge

Item 11 12 13 14

Designation Engine Control Unit (ECU) diagnostics socket Switch panel Indicator lamps Fuses

(1) Ignition switch With the key in the ignition switch, the following occurs: • Position 0 - Electric power is available for the lights, cab/hood raising, and the cab climate control system.

• Position I - The dashboard controls are operable.

• Position II - The engine will start.

NOTE: The ignition key is also used to lock and unlock the cab doors, the service hatch underneath the cab, and the tool kit.

SS12J281

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2

INTRODUCTION

(8) Engine speed selector Turn the selector dial to adjust the engine speed from maximum to minimum speed settings.

SS12J283

3

SS12J284

4

SS13G125

5

SS13G126

6

(9) Power View display The Power View display is a multifunctional display that provides information to the operator such as the fuel level, engine hours, engine RPM, coolant temperature, and several other engine function parameters. The display can be adjusted to the operator’s preference.

(10) Hydraulic oil temperature gauge This indicates hydraulic oil temperature during operation.

The optimal operating temperature is 50 - 60 °C (122 140 °F).

Oil viscosity class HV 100 HV 68 HV 46 HV 32

Highest permissible temperature 90 °C (194 °F) 90 °C (194 °F) 80 °C (176 °F) 70 °C (158 °F)

(11) Diagnostic port Use the diagnostic port to access the Engine Control Unit (ECU), engine actuator units, fault diagnostics, and parameter adjustments.

NOTE: The ECU is designed to process data about engine function and to control engine operation.

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INTRODUCTION

(12)

Switch panel Auxiliary lights (option)

Press the icon to turn ON the auxiliary lights. Press the blank side of the switch to turn OFF the auxiliary lights.

SS12J286

7

Fender lights (front and rear) and headlights This is a three position switch: • Top position - Press the blank side of the switch to turn OFF the fender lights and headlights.

• Middle position - Press the icon to turn ON the fender lights and illuminate the dashboard control panel • Bottom position - Press the icon to turn ON headlights.

Rear lights Press the icon to turn ON the rear work lights. Press the blank side of the switch to turn OFF the rear work lights.

Horn Press and hold the icon to sound the horn. Release the switch to deactivate the horn.

Engine idle adjustment

Engine idle speed can be adjusted from 800 - 1000 RPM. NOTE: The default setting is 850 RPM and the manufacturer recommends against adjustment for the reason that other machine parameters are set based off the default idle setting.

Engine idle switch This switch must be ON before starting the engine.

NOTE: This protects the engine from starting at high RPMs typically used during machine operation.

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INTRODUCTION

Beacon To use the beacon: • Plug the beacon cable into the socket on the rear of the machine.

• Press the icon to turn ON the beacon.

• Press the blank side of the switch to turn the beacon OFF. SS12J287

8

SS12J288

9

Hazard warning lights Engage hazards to warn others of possible hazardous situations near the machine.

• Press the icon to turn ON the hazard lights.

• Press the blank side to turn OFF the hazard lights.

Drum slip limitation switch (option) Use only to move the machine onto the loading area of a transport vehicle.

• Press the icon to turn ON the drum slip limitation.

• Press the blank side of the switch to turn OFF the drum slip limitation.

NOTE: If the machine is equipped with the drum slip limitation option, then the automated Anti-Slip Control (ASC) feature will not activate.

NOTE: When the drum slip limitation feature is ON, the vibration feature is blocked.

NOTE: The drum slip limitation will not activate if the machine is in transport speed mode . Turn the transport speed switch OFF before using the drum slip limitation function.

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SS12J288

10

INTRODUCTION

Vibration selector

The vibration selector switch has three positions: • Top position - High frequency, low amplitude. Recommended for granular materials.

• Middle position - OFF, neither vibration option is selected.

SS12J288

11

SS12J288

12

SS12J288

13

• Bottom position - Low frequency, high amplitude. Recommended for cohesive materials.

NOTE: Engage the vibration selection before the machine starts to move and stop the machine before changing the vibration selection.

NOTICE: It is not recommended to engage or change the vibration selection while the machine is moving.

Damage to the machine hydraulic components may occur that will shorten the life of the components.

Fan switch (cab only) The three position fan switch will enhance air flow inside the cab.

• Top position - Off • Middle position - Fan is on high • Bottom position - Fan is on low

Turn signals - direction indicators Use the turn signals to inform other motorist which direction you intend to turn the machine.

• Press the right side of the switch when turning to the right.

• Press the left side of the switch when turning to the left.

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INTRODUCTION

Compaction meter switch NOTE: The Operator's Manual for the Compaction Meter is supplied separately.

(13)

SS12J288

14

SS12J289

15

Indicator lamps Parking brake

The indicator lamp is lit when the parking brake is engaged.

Vibration The indicator lamp is lit when vibration is ON.

Direction indicators The indicator lamp flashes on and off when the turn signal is ON. NOTICE: Rapid flashing indicates a failure (defective bulb).

Travel controller - neutral (idle) position The indicator lamp is lit when the travel controller is in the neutral position.

NOTICE: Make sure the travel controller is in neutral before starting the engine.

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INTRODUCTION

NOTE: The Anti-Slip Control feature is standard equipment on the SV208 and SV210. It is optional on the SV212 and SV216 models.

Anti-Slip Control (ASC) The Anti-Slip Control (ASC) indicator lamp is ON when the ACS system senses a lack of traction. As a result the inter-axle differential lock is engaged. When traction is regained the ACS disengages and lamp turns OFF. NOTE: The SV208 and SV210 operators do not control the ASC feature, however the ACS feature will not engage when the drum slip limitation is active or if the transport speed switch is active.

SS12J291

16

SS12J289

17

NOTE: The SV212 and SV216 operators must press the ASC button (arrow) to activate and deactivate this feature.

WARNING Roll-over hazard!

Observe the maximum permissible gradient when driving uphill and across the slope.

The values given may be lower depending on traction conditions and the actual machine weight.

Failure to comply could result in death or serious injury.

W1067A

ROPS 2D - Roll Over Preventative System A flickering ROPS 2D indicator lamp with an acoustic alarm indicates that the machine is at a hazardous angle during cross travel on a slope. Vibration mode will disengage and will not turn on until the machine is at a safe angle.

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INTRODUCTION

Engine preheating When lit, the engine is preheating because of low ambient temperatures. Wait until the engine preheat lamp is off before attempting to start the engine.

SS12J289

18

Hydraulic oil filter clogged When lit, the hydraulic oil filter clogged.

NOTICE: Replace the hydraulic oil filter immediately.

Hydraulic oil level When the hydraulic oil level indicator lamp is on, the hydraulic oil level in the tank is below the minimum required level.

The machine will stop and the engine stalls.

NOTICE: The engine can be started once the defect has been repaired and oil in the hydraulic tank has been filled up to its recommended level.

Air filter clogged When lit, the air filter is clogged.

NOTICE: Replace the air filter immediately.

Battery lamp When lit, the machine is using battery power. The light must turn OFF once the machine’s engine is started. If the light remains lit while the engine is running, the machine is experiencing a charging issue.

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INTRODUCTION

Multifunctional display Item 1 2 3

4

5 6 7

Designation WARNING - amber LED lights Alarm for engine failure or minimal fuel level in tank.

SHUTDOWN - red LED lights Alarm for major engine malfunction.

ENTER Selects the Menu or parameter, and conceals or displays active error codes.

RIGHT arrow button - moves cursor up or right Illuminates data on the display or moves the parameter option to the right or down.

LEFT arrow button - moves cursor down or left Illuminates data on the display or moves the parameter option to the left or up.

MENU selection button To enter or exit Menu.

Display

SS12N052

19

NOTICE: If the red LED turns ON - reduce engine power, stop the machine immediately at a safe place, and shut off the engine. Do not operate the machine unless the defect has been repaired!

NOTICE: The amber LED light indicates engine failure. Reduce engine power, stop the machine immediately at a safe place, and shut off the engine. Do not operate the machine unless the defect has been repaired!

Right-hand side controls

(2) Travel controller

This travel controller is used to adjust driving direction and speed. Driving speed corresponds to the degree to which the travel controller is moved from the neutral (N) position.

The travel controller locks into the position it is moved to.

With the travel controller in the neutral (N) position the operator may turn the vibrations ON or OFF with the button (7) located on the travel controller.

SS12J282

20

NOTICE: Move the travel controller to the neutral (N) position before starting the engine.

(3) Transport speed switch With transport speed switch ON the machine will reach maximum speed at reduced tractive force when the travel controller is moved completely forward or backward.

NOTE: The operator may press the transport speed switch while the machine is moving.

NOTICE: Do not turn off the transport speed at high speed. Sudden deceleration (retardation) will occur followed by an impact within the hydraulic system. Turn off the transport speed at low speeds or when the machine is stationary.

(4) Speed selector

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INTRODUCTION

Select from three operating speeds while driving.

NOTE: The speed selection is ignored when the transport speed switch (3) is ON.

(5) Parking brake Press to engage or disengage the parking brake.

NOTE: If the machine is stationary and the operator stands up from the seat without first engaging the parking brake; the machine will brake automatically and the engine will shut OFF after 8 s.

(6) Emergency stop button In emergency situations press the emergency stop button. The machine immediately comes to a standstill, the engine shuts down, and the parking brake engages.

If the emergency stop button is pressed. The button remains engaged and the machine will not start until it is disengaged. To disengage, turn the push button clockwise approximately 1/4 turn until it releases.

NOTICE: Only press the emergency stop button in an emergency situation.

(7) Vibration button Press the vibration button on the travel controller to engage or disengage vibrations. Vibrations can be turned ON while driving.

Overhead controls Front Wiper switch

Rear Wiper switch

Fan switch – fan induces ambient air SS13G052

Windshield Washer switch

Item 1

Designation Cab light

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21

INTRODUCTION

Air conditioner (optional) Item 10 11 2A

Designation Air Conditioning switch – ON/OFF and temperature control Fan switch Air Recirculation switch

NOTICE: It is recommend that you start the air conditioner at least once every three weeks.

SS13G042

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22

INTRODUCTION

Consumables 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.

Recommended oil: – CASE AKCELA ENGINE OIL 15W-40 – CASE AKCELA NO. 1™ ENGINE OIL SAE 15W-40: All season – CASE AKCELA NO. 1™ ENGINE OIL SAE 10W-30: Winter – SAE 5W30: Arctic – API CI-4 oil is recommended – Year-round: CASE AKCELA ENGINE OIL 15W-40 , refer to figure 1.

• 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.

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INTRODUCTION

NOTICE: Do not allow the upper temperature limit to be exceeded for long periods of time as this will reduce the capabilities of the oil.

When using oil API CG-4/SH, the oil change interval must be reduced by half, i.e. 125 h.

Viscosity diagram

SS12C358

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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.

General specification – Biodiesel fuels Fatty Acid Methyl Ester Biodiesel (Biodiesel Fuel) consists of a family of fuels derived from vegetable oils treated with methylesters.

NOTICE: Biodiesel fuel blends are approved for your engine only if they comply with EN14214 specification standards or ASTM D6751.

NOTICE: It is imperative that you check with your CASE CONSTRUCTION dealer to find out which blend is approved for your engine. Be aware that use of Biodiesel fuel that does not comply with the standards mentioned above could lead to severe damage to the engine and fuel system of your machine. The use of fuels that are not approved may void CASE CONSTRUCTION warranty coverage.

Biodiesel fuel usage conditions NOTICE: The Biodiesel fuel must comply with the fuel specification indicated above.

Biodiesel fuel must be purchased from a trusted supplier that understands the product and maintains good fuel quality.

Biodiesel fuel must be preblended by the supplier. Mixing Biodiesel fuels on-site could result in an incorrect mixture that could lead to problems with both the engine and fuel system.

Engine performance is affected by the use of Biodiesel fuel. There may be up to 12 % reduction in power or torque depending on the blend used.

NOTICE: Do not modify the engine and/or injection pump settings to recover the reduced performance.

The reduced power must be accepted if using any Biodiesel fuel blend.

Some modification may be required to allow your engine to run on Biodiesel fuel. Consult your dealer for complete information on these modifications.

Biodiesel fuel has a higher cloud point than diesel fuel.

NOTICE: The use of high Biodiesel fuel blends are not recommended in cold weather conditions.

With Biodiesel fuels, it may be necessary to change the engine oil, engine oil filter and fuel filter elements more frequently than with diesel fuels. Biodiesel fuel can remove rust and particles from the inside of on-site fuel storage tanks that would normally adhere to the sides of the tank. Like particle deposits that commonly occur with diesel fuel, these particles can become trapped by the machine fuel filters, causing blockage and shortening filter life. This is more likely to happen in cold weather. Consult your CASE dealer for information on cold weather operation and proper maintenance intervals when using any Biodiesel fuel blend.

When handling Biodiesel Fuel, care must be taken not to allow water into the fuel supply. Biodiesel Fuel will actually attract moisture from the atmosphere.

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INTRODUCTION

Fuel tanks must be kept as full as possible to limit the amount of air and water vapors in them. It may be necessary to drain the fuel filter water trap more frequently.

Potential oxidation and stability could be a problem with the fuel stored in the machine.

NOTICE: Machines must not be stored for more than 3 months with Biodiesel fuel blends in the fuel system.

If longer storage periods are necessary, the engine must run on pure diesel fuel for a minimum of 20 h to flush the Biodiesel fuel out of the fuel system prior to storage.

NOTICE: Biodiesel Fuel must not be stored in on-site + tanks for more than three months.

Any spillage of Biodiesel fuel must be cleaned up immediately before it can cause damage to the environment and the paint finish of the machine.

Before using Biodiesel fuel blends you should consult with your dealer to receive full information about the approved blend for your machine and any detailed conditions of its usage.

NOTICE: Be aware that not fulfilling the requirements and conditions of Biodiesel fuel usage will void your machine’s CASE warranty coverage.

Coolant

WARNING Chemical hazard!

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

Failure to comply could result in death or serious injury.

W1109A

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

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

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

NOTICE: Do not use coolant with an antifreeze concentration greater than 50 % (point of congelation is -36 °C (-33 °F), 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

Transmission fluid Use CASE AKCELA GEAR 135 H EP 80W-90 for outdoor temperature -10.0 - 30.0 °C (14.0 - 86.0 °F).

Use CASE AKCELA TRANSAXLE FLUID 80W-140 for outdoor temperature 20.0 - 45.0 °C (68.0 - 113.0 °F).

NOTICE: The operating temperature of the fluid must not exceed 85 - 90 °C (185.0 - 194.0 °F).

Lube grease Use plastic lubricant with lithium content to lubricate the machine: Case Akcela Extreme pressure grease moly

Washer fluid Use water (up to 0 °C (32 °F) and motor vehicle glass washer fluid when filling the washer fluid reservoir.

NOTICE: Fill with a winter-rated motor vehicle glass washer fluid when temperatures are below 0 °C (32 °F).

Use plastic lubricant with lithium content to lubricate the machine: Case Akcela Extreme pressure grease moly

Vibrator cooling mixture (only for SV212 and SV216) Mixture SV212 • 22.0 l (5.8 US gal) of water • 50.0 kg (110.2 lb) 34 % of calcium chloride - CaCI2 Mixture SV216 • 30.0 l (7.9 US gal) of water • 66.6 kg (146.8 lb) 34 % of calcium chloride - CaCI2 Part

Type

Engine

Engine oil

Fuel tank

Hydrostatic system

Quantity SV 208

Quantity SV 210

Quantity SV 212

Quantity SV 216

7 l (1.85 US gal)

11 l (2.9 US gal)

Diesel

275 l (72.6 US gal)

410 l (108.3 US gal)

Hydraulic oil

73 l (19.3 US gal)

90 l (23.8 US gal)

As required

As required

Hinge bearings - steering joint Plastic grease and steering cylinders

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Icon

INTRODUCTION

Part

Type

Quantity SV 208

Quantity SV 210

Quantity SV 212

Quantity SV 216

Engine cooling Year round system antifreeze

24 l (6.36 US gal)

32 l (8.45 US gal)

Vibratory drum Engine oil

6.7 l (1.77 US gal)

8 l (2.1 US gal)

Drum transmission

Transmission fluid

2.5 l (0.66 US gal) (D) 2.8 l (0.74 US gal) (HT)

4.20 l (1.11 US 4.80 l (1.27 US gal) (D) gal) (D) 4.8 l (1.27 US 5.10 l (1.35 US gal) (HT) gal) (HT)

Axle transmission

Transmission fluid

2x 2.5 l (2x 0.66 US gal)

2x 2.8 l (2x 0.7 US gal)

Battery

Distilled water

Washers

Tires Vibrator cooling drum

Water and antifreeze agent at ratio required by outdoor temperature Air or liquid

As required

2.75 l (0.73 US gal)

2.75 l (0.73 US gal)

—

60 l (15.85 US 80.0 l (21.1 US gal) gal)

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Icon

INTRODUCTION

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

SS12K456

Item A B

Designation

1

Item C D

Front Rear

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Designation Left Right

INTRODUCTION

Product identification Designation Item 1 Product Identification Number (PIN) plate 2 Machine’s production number

SS13A883

1

SS13A882

2

SS12K516

3

Engine serial number Engine serial number location.

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INTRODUCTION

Part identification

SS12K457

Item 1 Vibratory drum 2 Drum frame

3 4 5 6 7 8 9 10 11 12

Designation

Scraper Joint Machine frame Axle Fuel tank Batteries Roll Over Protective System (ROPS) frame Hydraulic tank Cab or Canopy Hood

1

Item Designation 13 Engine 14 Radiator - Engine air cooler for intake manifold - Hydraulics cooler 17 Instrument panel 18 Drive motor 19 Compaction (vibration) motor 20 Exhaust muffler 21 Air filter 22 Dozer blade (option) 23 Pad foot segments (option) 24 Hydraulic oil pressure filter 25 Air conditioner

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SERVICE MANUAL Engine SV208 SV210 SV212 SV216

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Contents Engine - 10

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

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Engine - 10 Engine and crankcase - 001

SV208 SV210 SV212 SV216

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Contents Engine - 10 Engine and crankcase - 001

FUNCTIONAL DATA Engine Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SERVICE Engine Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Drain fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

DIAGNOSTIC Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

(*) See content for specific models 47688018 12/06/2014

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Engine - Engine and crankcase

Engine - Exploded view SV208 SV210

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Engine - Engine and crankcase

SS13A730

1

Engine

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Engine - Engine and crankcase

Engine table Position 1 2 3 4 5 6 7 11 12 13 14 15 16 17 18 19 20 26 27 28 29 35 36 37 38 39 40 41 42 44 45 51 57 59 60

Designation Front left bracket Front right bracket Holder Left bracket Right bracket Filter holder Rubber mounting Front bracket Left bracket Right bracket Holder Holder Washer Holder Washer Flat iron Holder Pipe Pipe Elbow Ring Cummins engine Fuel filter Flange Clutch Coupling Elbow Sleeve Plug Clamp of hose Rubber mounting Contactor Bolt Bolt Bolt

Position 61 62 63 64 65 66 67 68 70 71 72 79 80 81 82 84 85 87 88 92 94 96 98 105 106 107 108 109 112 113 114 117 120 121

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Designation Bolt Bolt Bolt Bolt Stud bolt Bolt Bolt Bolt Bolt Bolt Bolt Spring washer Washer Spring washer Washer Washer Washer Washer Washer Nut Nut Nut Nut Connecting pipe Bolt Packing ring Plug Terminal Shaft Shaft Shaft Link tape Clamp Cover

Engine - Engine and crankcase

SS13A734

2

Cooling system

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Engine - Engine and crankcase

Cooling system table Position 1 2 4 5 6 7 8 9 10 13 14 17 18 21 22 23 24 25 26 27 28 30 31 32

Designation Equalizer tank Pipe Holder Holder Spacing ring Spacing ring Elbow Clamp Spacing ring Steel plate Pipe Spacing ring Spacing ring Strap Packing Packing Packing Oil refusal hose Deaereting hose Deaereting hose Shaft Reducing piece Coupling Cooler

Position 33 35 36 37 38 39 41 42 43 44 47 51 52 53 54 57 58 59 64 66 67 69 70 71

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Designation Cover Coupling Link tape Oil level gauge Clamp Clamp Clamp Clamp Clamp of hose Clamp of hose Clamp Bolt Bolt Bolt Bolt Locking nut Nut Nut Washer for wood Spring washer Washer Washer Washer Washer

Engine - Engine and crankcase

SS13A736

3

Intake and exhaust

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Engine - Engine and crankcase

Intake and exhaust table Position 1 2 3 4 5 9 10 11 14 15 16 18 19

Designation Exhaust Orifice plate Sleeve Filter holder Bracket Nut Cylinder Sleeve Clamp Sleeve Exhaust Elbow Air cleaner

Position 20 21 22 23 27 28 29 30 31 32 35 41 42

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Designation Indicator Bracket Clamp Clamp Bolt Bolt Bolt Bolt Bolt Bolt Nut Washer Washer

Engine - Engine and crankcase

Engine - Exploded view SV212 SV216

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Engine - Engine and crankcase

SS13A731

1

Engine

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Engine - Engine and crankcase

Engine table Position 1 2 4 5 6 7 8 11 12 13 14 18 19 20 23 24 25 26 27 29 30 31 33 34 35 36 40 41 42 43 44 45 46 49

Designation Left bracket Right bracket Rubber mounting Left bracket Right bracket Holder Ring Holder Flange Washer Filter holder Front bracket Lower bracket Lower bracket Insert Pipe Pipe Fuel filter Coupling Clamp of hose Clamp of hose Clamp of hose Holder Holder Connecting pipe Cummins engine Elbow Bolt Bolt Bolt Bolt Bolt Bolt Bolt

Position 50 51 52 55 60 61 62 63 65 66 67 68 69 70 71 72 73 74 75 79 80 81 82 83 86 91 92 93 95 108 113 114 115

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Designation Bolt Bolt Bolt Bolt Nut Nut Nut Nut Washer Washer Washer Spring washer Spring washer Washer Washer Washer Washer Washer Washer Coupling Connecting pipe Connecting pipe Connecting pipe Contactor Hydraulic clutch Hose Hose Hose Silent block Clamp Sleeve Cover Link tape

Engine - Engine and crankcase

SS13A735

2

Cooling system

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Engine - Engine and crankcase

Cooling system table Position 1 2 4 5 6 7 10 13 14 15 17 18 21 22 23 24 25 26 27 28 32 33 34 35

Designation Equalizer tank Lower pipeline Holder Holder Spacing ring Spacing ring Spacing ring Steel plate Piping Clamp Spacing ring Spacing ring Strap Packing Packing Side seal Hose Deaereting hose Deaereting hose Hose Cooler Cover Rubber elbow Rubber elbow

Position 36 37 38 39 40 41 42 43 44 45 49 52 53 54 58 59 64 65 66 67 69 70 71

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Designation Link tape Oil level gauge Clamp Clamp Rubber elbow Clamp Clamp Clamp of hose Clamp of hose Clamp of hose Bolt Bolt Bolt Bolt Nut Nut Washer for wood Spring washer Spring washer Washer Washer Washer Washer

Engine - Engine and crankcase

SS13A736

3

Intake and exhaust

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Engine - Engine and crankcase

Intake and exhaust table Position 1 2 3 4 5 8 9 10 13 14 15 16 18 19

Designation Exhaust Reducing piece Filter holder Sleeve Support Nut Cylinder Steel plate Sleeve Clamp Sleeve Exhaust adapter Elbow Air cleaner

Position 20 21 22 23 27 28 29 30 31 32 35 41 42

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Designation Indicator Sleeve Clamp Clamp Bolt Bolt Bolt Bolt Bolt Bolt Nut Washer Washer

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 SV208 SV210

NOTICE: Collect drained oil and do not let it soak into the ground.

1. Remove the drain plug and let oil pour out into an 8 l (2.1 US gal) container.

2. Reinstall the plug.

SS12J411

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1

Engine - Engine and crankcase

Engine - Remove SV208 SV210

NOTE: For more details, refer to Engine - Exploded view (10.001), Hydrostatic transmission - Component identification (29.202).

1. Lift the hood and support it in the lifted position with adequate lifting equipment (1).

2. Disconnect the electrical wiring.

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SS13A845

1

SS13A846

2

Engine - Engine and crankcase

3. Press out the pins from the piston ends in the lifting cylinder; and secure with adequate lifting equipment.

SS13A847

3

SS13A848

4

SS13A849

5

SS13A850

6

4. Install a suitable tool (3) to lower and support the hood.

5. Remove the hinges.

6. Attach a suitable lifting tool (3).

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Engine - Engine and crankcase

7. Lift the hood and set the hood aside.

SS13A851

7

SS13A852

8

SS13A853

9

8. Undo the filler neck and drain the coolant.

9. Drain the coolant into a suitable container.

SS13A854

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10

Engine - Engine and crankcase

10. Disconnect the hoses (27) and (28) and the rubber elbow (35).

11. Remove the hoses (93) and (94) of the hydraulic oil radiator and plug the outlets.

SS13F001

11

SS13F165

12

SS13F002

13

12. Remove the holders.

13. Undo the bolts (53).

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Engine - Engine and crankcase

14. Suspend the radiator by hooks and move it aside.

SS13F003

14

SS13F004

15

SS13F005

16

SS13F006

17

15. Remove the hydraulic tank cover.

16. Remove the suction hose (53) for the steering pump from the hydraulic tank.

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Engine - Engine and crankcase

17. Plug the outlet.

SS13F007

18

SS13F161

19

SS13F155

20

SS13F008

21

18. Disconnect the steering pump hoses and plug the outlet.

19. Undo the bolt of the clamp (23) on the turbo.

20. Remove the four bolts (28) on the air filter holder.

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Engine - Engine and crankcase

21. Disconnect the filter sensor wiring and move the filter aside.

SS13F009

22

SS13F010

23

SS13F011

24

SS13F012

25

22. Undo the clamp on the exhaust pipe (14).

23. Remove the exhaust pipe holder bolts (31).

24. Set the muffler aside.

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Engine - Engine and crankcase

25. Plug the outlets.

SS13F013

26

SS13F014

27

SS13F016

28

SS13F017

29

26. Disconnect all wires • ground strip • starter wires • alternator wires • water temperature • oil pressure sensor • RPM meter • injection pump solenoid

27. Disconnect the fuel intake and overflow.

28. Raise the cab with a hydraulic lift. Use adequate lifting equipment (1) to unload the piston of the lifting cylinder.

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Engine - Engine and crankcase

29. Remove the bolts.

Set the rubber partition aside.

SS13F018

30

SS13F230

31

SS13F019

32

SS13F231

33

30. Remove the bolts (66) from the flange (37).

31. Suspend the pump on adequate lifting equipment.

32. Slide it out of the clutch (38) and support it.

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Engine - Engine and crankcase

33. Remove the nuts (96) of the front engine rubber mounting.

SS13F232

34

SS13F234

35

SS13F175

36

SS13F167

37

34. Remove the bolts (71) of the rear brackets.

35. Mount a suitable lifting tool (5) to the flange. Suspend the engine.

36. Extract the engine and set it aside on support no. (4).

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Engine - Engine and crankcase

Engine - Install SV208 SV210

NOTE: For more details, refer to Engine - Exploded view (10.001), Hydrostatic transmission - Component identification (29.202)..

1. Mount an adequate lifting device (5) to the flange. Suspend the engine.

SS13F175

1

SS13F234

2

SS13F232

3

2. Install the bolts (71) for the rear brackets.

3. Install the nuts (96) for the front engine rubber mounting.

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Engine - Engine and crankcase

4. Slide the engine into the clutch (38).

SS13F231

4

SS13F230

5

SS13F018

6

SS13F016

7

5. Install the bolts (66).

6. Install the rubber partition.

7. Connect the fuel intake and overflow.

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Engine - Engine and crankcase

8. Connect all wires • ground strip • starter wires • alternator wires • water temperature • oil pressure sensor • RPM meter • injection pump solenoid

SS13F014

8

SS13F011

9

9. Install the muffler.

10. Install the clamp on the exhaust pipe (14).

SS13F010

10

SS13F008

11

11. Install the air filter assembly.

12. Connect the air filter sensor.

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Engine - Engine and crankcase

13. Install the clamp (23) on the turbo.

SS13F155

12

SS13F161

13

SS13F006

14

SS13F005

15

14. Connect the steering pump hoses.

15. Install the suction hose (53) for the steering pump.

16. Install the hydraulic tank cover.

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Engine - Engine and crankcase

17. Suspend the radiator in position.

SS13F003

16

SS13F002

17

SS13F165

18

SS13F001

19

18. Install the bolts (53) for the radiator.

19. Install the holders.

20. Connect the hoses (27) and (28) and the rubber elbow (35).

21. Connect the hoses (93) and (94) for the hydraulic oil radiator.

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Engine - Engine and crankcase

22. Lower the hood into position.

SS13A851

20

SS13A849

21

SS13A847

22

23. Install the hinges.

24. Insert the pins into the piston ends of the lifting cylinder.

25. Connect the electrical wiring.

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Engine - Engine and crankcase

Engine - Remove SV212 SV216

NOTE: For more details, refer to Engine - Exploded view (10.001), Hydrostatic transmission - Component identification (29.202).

1. Lift the hood and support it in the lifted position with adequate lifting equipment (1).

2. Disconnect the electrical wiring.

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SS13A845

1

SS13A846

2

Engine - Engine and crankcase

3. Remove the pins from the piston ends in the lifting cylinders..

SS13A847

3

SS13A848

4

SS13A849

5

SS13A850

6

4. Install a suitable tool (3) to lower and support the hood.

5. Remove the hinges.

6. Attach a suitable lifting tool (3).

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Engine - Engine and crankcase

7. Lift the hood and set the hood aside.

SS13A851

7

SS13A852

8

SS13A853

9

8. Undo the filler neck and drain the coolant.

9. Drain the coolant into a suitable container.

SS13A854

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10

Engine - Engine and crankcase

10. Disconnect the hoses (27) and (28) and the rubber elbow (35).

11. Remove the hoses (93) and (94) of the hydraulic oil radiator and plug the outlets.

SS13F001

11

SS13F165

12

SS13F002

13

12. Remove the holders.

13. Loosen the bolts (53).

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Engine - Engine and crankcase

14. Suspend the radiator by hooks and move it aside.

SS13F003

14

SS13F004

15

SS13F005

16

SS13F006

17

15. Remove the hydraulic tank cover.

16. Remove the suction hose (53) for the steering pump from the hydraulic tank.

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Engine - Engine and crankcase

17. Plug the outlet.

SS13F007

18

SS13F161

19

SS13F155

20

SS13F008

21

18. Disconnect the steering pump hoses and plug the outlet.

19. Undo the bolt of the clamp (23) on the turbo.

20. Remove the four bolts (28) on the air filter holder.

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Engine - Engine and crankcase

21. Disconnect the filter sensor wiring and move the filter aside.

SS13F009

22

SS13F010

23

SS13F011

24

SS13F012

25

22. Loosen the clamp on the exhaust pipe (14).

23. Remove the exhaust pipe holder bolts (31).

24. Set the muffler aside.

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Engine - Engine and crankcase

25. Plug the outlets.

SS13F013

26

SS13F014

27

SS13F015

28

SS13F016

29

26. Disconnect all wires • ground strip • starter wires • alternator wires • water temperature • oil pressure sensor • RPM meter • injection pump solenoid

27. Disconnect the control unit of the engine.

28. Disconnect the fuel intake and overflow.

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Engine - Engine and crankcase

29. Raise the cab with a hydraulic lift. Use adequate lifting equipment to unload the piston.

SS13F017

30

SS13F018

31

SS13F238

32

SS13F019

33

30. Remove the bolts.

31. Set the rubber partition aside.

32. Remove the bolts (45) from the flange (12).

33. Suspend the pump on adequate lifting equipment.

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Engine - Engine and crankcase

34. Slide it out of the clutch (86) and support it.

SS13A496

34

SS13F156

35

SS13A505

36

SS13F175

37

35. Remove the nuts (63) of the front engine rubber mounting.

36. Remove the nuts (71) of the right brackets.

37. Mount a suitable lifting device (5) to the flange.

38. Suspend the engine, using adequate lifting equipment.

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Engine - Engine and crankcase

39. Extract the engine and set it aside on support no. (4).

SS13F167

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38

Engine - Engine and crankcase

Engine - Install SV212 SV216

NOTE: For more details refer to Engine - Exploded view (10.001), Hydrostatic transmission - Component identification (29.202).

1. Lower the engine into position.

SS13F175

1

SS13A505

2

SS13F156

3

2. Install the right brackets.

3. Install the front, engine rubber mounts.

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Engine - Engine and crankcase

4. Slide the engine into the clutch.

SS13A496

4

SS13F238

5

SS13F018

6

SS13F016

7

5. Install the bolts (45).

6. Install the rubber partition.

7. Connect the fuel intake and overflow.

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Engine - Engine and crankcase

8. Connect the control unit on the engine.

SS13F015

8

SS13F014

9

9. Connect all wires • ground strip • starter wires • alternator wires • water temperature • oil pressure sensor • RPM meter • injection pump solenoid

10. Install the muffler.

SS13F011

10

SS13F010

11

11. Attach the exhaust pipe (14).

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Engine - Engine and crankcase

12. Install the air filter assembly.

13. Connect the filter sensor.

SS13F008

12

SS13F155

13

SS13F161

14

SS13F006

15

14. Install the clamp (23) on the turbo.

15. Connect the steering pump hoses.

16. Install the suction hose (53) for the steering pump on the hydraulic tank.

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Engine - Engine and crankcase

17. Install the hydraulic tank cover.

SS13F005

16

SS13F003

17

SS13F002

18

SS13F165

19

18. Lower the radiator into position.

19. Install the bolts (53).

20. Install the holders.

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Engine - Engine and crankcase

21. Connect hoses (27) and (28) and the rubber elbow (35).

22. Install hoses (93) and (94) onto the hydraulic oil radiator.

SS13F001

20

SS13A851

21

SS13A849

22

SS13A847

23

23. Lower the hood into position.

24. Install the hinges.

25. Install the pins for the piston ends in the lifting cylinders.

26. Connect the electrical wiring.

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Engine - Engine and crankcase

Engine - Troubleshooting Problem Engine does not start even though starter is cranking.

Possible Cause Empty fuel tank

Correction • Replenish fuel • Bleed the fuel system.

Fuel system leaks

• Inspect the connections for leaks.

• Eliminate leaks.

• Prime the fuel with the hand priming pump.

Air in the fuel system Bleed the fuel system.

Clogged precleaner, fuel cleaner or distri- • Clean the distribution system. bution system.

• Replace the filter elements.

Precleaner, fuel cleaner or distribution sys- • Clean the system. tem clogged with paraffi n deposits in the • Use winter-grade fuel. winter.

The starter turns slowly – poorly charged • Inspect the state of the battery. battery, oxidized terminals or loose clamps • Replenish electrolyte. at the terminals.

• Clean the contacts.

• Grease and tighten the clamps.

Use oil suitable for the actual ambient temperature.

The engine is stopped after starting by the Replenish hydraulic oil up to the prescribed level. “engine shut-off” device.

The hydraulic oil level indicator lamp is on.

The engine is stopped after starting by the • Check the hydraulic oil level indicator “engine shut-off” device. lamp.

The hydraulic oil level indicator lamp is off. Check voltage at the engine stop • magnet Y5 (inspect the fuse F3, cables, relay K3, connectors).

Faulty delivery valve at the injection pump. Contact your authorized engine dealer.

Engine does not start and The machine electrical system is discon- Turn on the battery master switch to actistarter does not crank. nected. vate the electrical system.

Starting conditions are not met.

The tilting arm of the travel controller is lifted or the emergency brake button is depressed.

The travel controller is not in the neutral Move the travel controller to the neutral poposition and the neutral position indicator sition. lamp is off.

Faulty battery or connections.

• Test the battery voltage, Oil used too dense during winter season.

• Check the cables and connections.

Inspect the starter connection and check whether the pinion shifts out.

Switch box Check the function and connection of the switch box (cables, function of the relay K4, terminal switches S13, S10, S11, terminals, etc.).

Mechanical failure of the engine, the clutch Verify whether the engine can turn over by or the hydrostatic system. turning the belt pulley at the crankshaft.

Insufficient coolant • Quickly stop the engine.

Starter

Engine is overheating.

• Replenish coolant.

Clogged radiator Incorrect belt tension or broken belt.

• Find the leak and repair it.

Clean the radiator.

• Adjust the tension.

• Replace the belt.

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Engine - Engine and crankcase

Problem

Possible Cause Malfunctioning thermostat.

High amount of dirt and deposits in the cooling circuit.

Faulty injection nozzles.

Incorrect amount of fuel supplied by the injection pump.

Ambient temperature too high.

Insufficient engine lubrication – the lubrication indicator lamp is on.

Engine runs irregularly with low power.

Engine smokes excessively.

Correction • Verify thermostat functionality.

• Replace if necessary.

Clean the cooling circuit.

Contact your authorized engine dealer.

Contact your authorized engine dealer.

Improperly adjusted injection start.

Engine oil level too low.

Work for a limited time and allow the engine to cool down.

Contact your authorized engine dealer.

Replenish the oil.

Engine oil is leaking.

• Immediately stop the engine.

Oil used is of incorrect viscosity.

Overheated engine

• Inspect lubrication system connections and repair any leaks.

Exchange oil for a recommended type.

• Allow the engine to cool down.

Air in the fuel system

• Troubleshoot to determine the reason.

• Bleed the fuel system.

Faulty injection nozzles Incorrect valve clearance Broken injection pipe Improperly adjusted injection pump Increased negative pressure in the engine intake manifold.

• Repair any leaks.

Contact your authorized engine dealer.

Contact your authorized engine dealer.

Contact your authorized engine dealer.

Contact your authorized engine dealer.

• Check function of the vacuum switch.

• Replace the filter elements if needed.

Reduce oil level to the upper mark on the dipstick.

Incorrect compression due to burned or Contact your authorized engine dealer. broken piston rings or incorrect valve clearance.

Repair any leaks.

Oil system leakage Oil level too high.

Excessive engine oil consumption

Leaking piston rings or generally worn engine.

Insufficient engine power Excessively clogged fuel cleaners Incorrect valve clearance.

Clogged injection nozzle holes.

Injectors are not adjusted to correct injection pressure.

Improperly adjusted injection pump.

Improperly adjusted advanced injection angle The cylinders have insufficient compression pressure.

Turbocharger fault.

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Contact your authorized engine dealer.

Replace the filter elements.

Adjust valve clearance.

Contact your authorized engine dealer.

Contact your authorized engine dealer.

Index Engine - 10 Engine and crankcase - 001 Engine - Drain fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Engine - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Engine - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Engine - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Engine - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Engine - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Engine - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Engine - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

(*) See content for specific models 47688018 12/06/2014

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Engine - 10 Engine cooling system - 400

SV208 SV210 SV212 SV216

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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

SS12K158

2

SS12K159

3

1. Remove the expansion tank cap.

NOTICE: Change coolant after engine operation has ended or after first heating the coolant to 80 °C (176 °F) through engine operation.

2. Remove the drain plug.

3. Let the coolant flow into a container.

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Index Engine - 10 Engine cooling system - 400 Radiator - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. © 2014 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.

47688018 12/06/2014 EN

SERVICE MANUAL Power coupling SV208 SV210 SV212 SV216

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Contents Power coupling - 19

[19.110] Flywheel damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1

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Power coupling - 19 Flywheel damper - 110

SV208 SV210 SV212 SV216

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Contents Power coupling - 19 Flywheel damper - 110

SERVICE Flywheel damper Adjust - Pump-drive coupling (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(*) See content for specific models 47688018 12/06/2014

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Power coupling - Flywheel damper

Flywheel damper - Adjust - Pump-drive coupling SV212 SV216

1. Install the (A) segments to the balance wheel.

2. Center the segments using an adequate tool (2) .

3. Lubricate the bolt (T1) under the head with grease.

4. Tighten to 155.0 - 165.0 N·m (114.3 - 121.7 lb ft).

5. Check the position.

SS13F148

1

SS13F298

2

SS13F060

3

SS13F062

4

6. Fix the flange (12) on the flange of the hydrostatic drive pump and the coupling (86) with (B) segments.

7. Tighten the bolt (T2) of the coupling (86) to 120.0 N·m (88.5 lb ft).

8. When installing the coupling (86), define axial clearance between the balance wheel face and the elastic element of the clutch.

9. Measure the distance (a) from the face of the balance wheel box.

10. Measure distance (b) from the elastic element face to the seating area of the flange (12).

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Power coupling - Flywheel damper

Difference in the distances a – b = 1 - 3 mm (3/64 - 1/8 in).

Colored (e. g. blue) material is deposited on the thread of the supplied countersunk hexagonal screws. Such material includes a film of adhesive and prevents its releasing. After screwing the bolts, the adhesive material requires four to five hours at an ambient temperature of 20 °C (68 °F) for hardening. The machine must not be operated until this time period has elapsed. Full hardening is complete after twenty four hours. Hardening can occur more quickly at higher temperatures, e.g. fifteen minutes at 70 °C (158 °F) (heating via a hot-air fan). Temperature stability of the bolts is between -80 - +90 °C (-112 - +194 °F) and the bolts can be used no more than three times. The adhesive material is sometimes wiped off and is deposited between the head of the bolt and the segment. This is not a defect, rather an advantage —both areas will adhere to each other better. If original supplied bolts are not available, both the bored thread and bolt must be carefully degreased and a layer of LOCTITE® 243 should be applied.

Spring washers are not allowed!

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SS13F335

5

Index Power coupling - 19 Flywheel damper - 110 Flywheel damper - Adjust - Pump-drive coupling (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(*) See content for specific models 47688018 12/06/2014

19.1 [19.110] / 5

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

PRINTED IN U.S.A. © 2014 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.

47688018 12/06/2014 EN

SERVICE MANUAL Hydrostatic drive SV208 SV210 SV212 SV216

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29

Contents Hydrostatic drive - 29

[29.218] Pump and motor components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.1 [29.202] Hydrostatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.2

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Hydrostatic drive - 29 Pump and motor components - 218

SV208 SV210 SV212 SV216

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Contents Hydrostatic drive - 29 Pump and motor components - 218

FUNCTIONAL DATA Pump Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

(*) See content for specific models 47688018 12/06/2014

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Hydrostatic drive - Pump and motor components

Pump - Component identification SV208 SV210

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Hydrostatic drive - Pump and motor components

SS13A733

Position 1 Bolt 2 Not used

Designation

1

Position Designation 8 Vibration pump 9 Steering pump 47688018 12/06/2014

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Hydrostatic drive - Pump and motor components

Position 3 4 5 6 7

Designation Bolt Bolt Not used Not used Hydrostatic drive pump

Position 10 11 12 13 14

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Designation Not used Washer Washer O-ring O-ring

Hydrostatic drive - Pump and motor components

Pump - Remove NOTE: For more details refer to Main drive clutch system - Component identification (35.860).

1. Raise the cab with a hydraulic lift. Use a suitable lifting device to unload the piston of the lifting cylinder.

SS13F041

1

SS13F042

2

SS13F043

3

SS13F044

4

2. Remove the bolts.

3. Set the rubber partition aside.

4. Remove the hose clamps.

5. Disconnect the wiring to the pump.

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Hydrostatic drive - Pump and motor components

6. Remove the hoses from the pump.

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SS13F045

5

SS13F046

6

SS13F047

7

SS13F048

8

Hydrostatic drive - Pump and motor components

7. Plug the outlets of the pump and hose ends.

SS13F049

9

SS13F050

10

SS13F051

11

SS13F158

12

8. Remove the bolts of the steering pump.

9. Put the steering pump aside.

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Hydrostatic drive - Pump and motor components

10. Suspend the vibration pump on the suitable lifting device .

11. Remove the bolts connecting both pumps.

SS13F052

13

SS13F159

14

SS13F053

15

SS13F054

16

12. Slide out and set aside.

13. Suspend the hydrostatic drive pump on the suitable lifting device .

14. Remove the bolts (66) from the flange (37).

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Hydrostatic drive - Pump and motor components

15. Slide it out of the clutch (38).

SS13F055

17

SS13F056

18

16. Set the hydrostatic drive pump with flange aside.

17. Remove the bolts (1) and the flange (37).

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Hydrostatic drive - Pump and motor components

Pump - Install NOTE: For more details refer to Main drive clutch system - Component identification (35.860).

1. Connect the hydrostatic drive pump to the flange (37).

SS13F056

1

SS13F054

2

SS13F052

3

SS13F158

4

2. Slide the assembly into the clutch (38).

3. Install the bolts (66) into the flange (37).

4. Mount the vibration pump.

5. Install the steering pump.

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Hydrostatic drive - Pump and motor components

6. Install the hoses on the pump.

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SS13F045

5

SS13F046

6

SS13F047

7

SS13F048

8

Hydrostatic drive - Pump and motor components

7. Connect the wiring to the pump.

SS13F044

9

8. Install the hose clamps.

SS13F043

10

SS13F042

11

9. Install the rubber partition.

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Index Hydrostatic drive - 29 Pump and motor components - 218 Pump - Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

(*) See content for specific models 47688018 12/06/2014

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Hydrostatic drive - 29 Hydrostatic transmission - 202

SV208 SV210 SV212 SV216

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Contents Hydrostatic drive - 29 Hydrostatic transmission - 202

FUNCTIONAL DATA Hydrostatic transmission Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

(*) See content for specific models 47688018 12/06/2014

29.2 [29.202] / 2

Hydrostatic drive - Hydrostatic transmission

Hydrostatic transmission - Dynamic description In a closed loop, hydrostatic transmission, the engine provides power to a hydrostatic pump assembly that sends hydraulic oil to the drive motors. In a hydrostatic, closed loop system, the hydrostatic pump and the drive motor are directly connected; the hydrostatic pump sends oil to the drive motor and the drive motor returns the oil back to the hydrostatic pump.

RAPH14SSL0013AA

1

Basic, hydrostatic, closed loop system Hydrostatic system components (1) Hydrostatic pump (2) Charge relief valve

(3) Drive motor (4) Main relief valve

(5) Check valve (6) Charge pump

Because of the high pressures required to move the machine, some of the oil in the hydrostatic, closed loop system leaks into the case drain and flushing valve of the components. This lost oil must be resupplied to keep the closed loop system working as designed. A charge pump (6) is used to supply this lost oil. Located on the hydrostatic pump assembly (1), the charge pump (6) supplies cooled, filtered oil from the reservoir to the closed loop system.

When the machine is traveling, the drive side of the closed loop has pressures too high to allow flow from the charge pump (6), but the return side of the closed loop has pressures similar to the charge pump’s pressure. The return side of the closed loop is where fresh, charge pump oil will enter into the closed loop from the charge pump (6). Charge pump oil also enters the closed loop when the machine is in neutral, because pressure inside the closed loop while in neutral is less-than-or-equal-to the charge pump’s pressure. To prevent closed loop oil from escaping back into the charge side of the system, a check valve (5) is placed between the supply of charge pump oil and each side of the closed loop.

While the machine is traveling, the load on the drive motor (3) can increase which causes the pressure in the closed loop to become excessive. A main relief valve (4) is installed on each side of the closed loop to limit the maximum pressure. These main relief valves (4) are nonadjustable and operate in only one direction.

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Hydrostatic drive - Hydrostatic transmission

Hydrostatic transmission - Component identification SV208 SV210

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Hydrostatic drive - Hydrostatic transmission

SS13A830

Position 2 Cube 3 Holder

Designation

1

Position 83 Hose 85 Hose 47688018 12/06/2014

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Designation

Hydrostatic drive - Hydrostatic transmission

Position 5 10 11 12 14 16 17 18 21 22 25 26 28 29 31 33 34 35 36 37 41 42 43 46 49 52 55 58 59 62 63 64 66 67 68 69 79 80 82

Designation Bracket Pipe Pipe Pipe Pipe Pipe Pipe Pipe Block Connecting pipe Connecting pipe Connecting pipe Connecting pipe Connecting pipe Connecting pipe Connecting pipe Connecting pipe Connecting pipe Connecting pipe Connecting pipe Coupling Coupling Coupling Coupling T Coupling T Reducing piece Plug Fast coupling Fast coupling Yoke Yoke Yoke O- ring O- ring O- ring O- ring Hose Hose Hose

Position 87 88 89 91 93 94 96 97 99 100 101 102 104 106 107 108 109 110 111 113 116 117 120 121 122 123 125 128 129 132 133 134 135 138 140 141 144 147 149

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Designation Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose Sleeve Clamp Sleeve Clamp Sleeve Sleeve Sleeve Cover Cover Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Washer Washer Link tape

Hydrostatic drive - Hydrostatic transmission

Hydrostatic transmission - Component identification SV212 SV216

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Hydrostatic drive - Hydrostatic transmission

SS13A831

1

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Hydrostatic drive - Hydrostatic transmission

Position 1 2 3 4 5 6 7 8 9 10 11 12 14 16 17 18 20 21 24 27 29 30 31 33 36 37 39 42 44 49 50 52 53 54 56 57 58 68 69 71 72 74

Designation Clamp Bracket Connecting pipe Connecting pipe Cube Holder Holder Washer Spreader Pipe Pipe Pipe Pipe Pipe Pipe Pipe Connecting pipe Block Connecting pipe Connecting pipe Connecting pipe Connecting pipe Connecting pipe Connecting pipe Coupling T Coupling T Coupling Coupling Plug Fast coupling Fast coupling Yoke Yoke Yoke O-ring O-ring O-ring Hose Hose Hose Hose Hose

Position 76 77 78 80 81 83 84 86 87 88 89 90 92 93 94 95 96 97 99 101 104 105 106 107 110 111 112 113 116 117 118 119 120 121 124 125 126 129 132 134 138

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Designation Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose Hose Sleeve Sleeve Clamp Sleeve Sleeve Sleeve Cover Packing ring Bolt Bolt Bolt Bolt Countersink Countersink Bolt Bolt Bolt Bolt Bolt Bolt Bolt Stud bolt Bolt Bolt Bolt Nut Washer Washer Link tape

Index Hydrostatic drive - 29 Hydrostatic transmission - 202 Hydrostatic transmission - Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydrostatic transmission - Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Hydrostatic transmission - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(*) See content for specific models 47688018 12/06/2014

29.2 [29.202] / 10

47688018 12/06/2014

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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. © 2014 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.

47688018 12/06/2014 EN

SERVICE MANUAL Brakes and controls SV208 SV210 SV212 SV216

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33

Contents Brakes and controls - 33

[33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1

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

SV208 SV210 SV212 SV216

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

SERVICE Parking brake external control Tool connection - Release the brakes for towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Brakes and controls - Parking brake or parking lock

Parking brake external control - Tool connection - Release the brakes for towing WARNING Unexpected machine movement!

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

Failure to comply could result in death or serious injury.

W1221A

1. Disconnect the hose (1) in the quick-coupling (2).

2. Loosen the hose (3) in the clamp, and the hose (3) connect with the quick coupling (2).

SS13G152

1

SS13G153

2

SS13F295

3

3. Disable the circuits on the hydraulic drive pump by loosening the center parts of both multifunctional valves and turning three times in the counter–clockwise direction.

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Brakes and controls - Parking brake or parking lock

4. Pump with the use of the hand pump.

SS13F296

4

SS13F297

5

5. Watch until the brake indicator lamp goes OFF with the ignition key turned ON.

The brakes of the machine have been released now (e.g. for towing).

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Index Brakes and controls - 33 Parking brake or parking lock - 110 Parking brake external control - Tool connection - Release the brakes for towing . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. © 2014 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.

47688018 12/06/2014 EN

SERVICE MANUAL Hydraulic systems SV208 SV210 SV212 SV216

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35

Contents Hydraulic systems - 35

[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.995] Compaction/vibration hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3

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Hydraulic systems - 35 Hydraulic systems - 000

SV208 SV210 SV212 SV216

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Contents Hydraulic systems - 35 Hydraulic systems - 000

FUNCTIONAL DATA Hydraulic systems Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic schema (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic schema (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Hydraulic schema (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

SERVICE Hydraulic systems Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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Hydraulic systems - Component localisation

RAIL14COM0406GA

1

Component location Component identification (1) (2) (3) (4)

Drive motor Dozer blade valve Flushing block Thermoregulator

(5) Brake valve (6) Hydraulic tank (7) Hydraulic oil cooler (8) Radiator/Inner cooler

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(9) RTM module/Divider block (10) Hydrostatic drive pump (11) Vibration pump (12) Steering pump

Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic schema SV208 SV210

NOTE: All numerical values on the schematics are metric.

Schematic guide Line color Red Blue Green Yellow

Description Operating pressure Return to reservoir Charge pressure Metered flow through restriction valve

Wheel differential lock Position 1 2 3 4 5 6 7

Designation Power-assisted steering valve Drum travel motor Lifting valve SMA 03 lifting unit Filler neck Thermoregulator Vibration motor

Position 8 9 10 11 12 13 14

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Designation Vibration pump Hydrostatic drive pump Flushing block Filter Brake valve RTM module Travel motor

Hydraulic systems - Hydraulic systems

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Wheel differential lock

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RAIL14COM0384JA-01

1

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Interaxle differential lock ATC Position 1 2 3 4 5 6 7

Designation Power-assisted steering valve Travel motor, drum Lifting valve SMA 03 lifting unit Filler neck Thermoregulator Vibration motor

Position 8 9 10 11 12 13 14

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Designation Vibration pump Hydrostatic drive pump Flushing block Filter Brake valve Divider block Travel motor, wheel

Hydraulic systems - Hydraulic systems

Interaxle differential lock ATC

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RAIL14COM0385JA

2

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Hydraulic systems - Hydraulic schema SV212

NOTE: All numerical values on the schematics are metric.

Schematic guide Line color Red Blue Green Yellow

Description Operating pressure Return to tank Charge pressure Metered flow through restriction valve

INTER - Wheel differential lock Position 1 2 3 4 5 6 7

Designation Power-assisted steering valve Drum, travel motor Filler neck Thermoregulator Vibration motor Vibration pump Hydrostatic drive pump

Position 8 9 10 11 12 13

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Designation Flushing block Filter Brake valve Not used Divider block Wheel, travel motor

Hydraulic systems - Hydraulic systems

INTER - Wheel differential lock

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RAIL14COM0392JA

1

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Interaxle differential lock ATC Position 1 2 3 4 5 6

Designation Power-assisted steering valve Drum, travel motor Filler neck Thermoregulator Vibration motor Vibration pump

Position 7 8 9 10 11 12

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Designation Hydrostatic drive pump Flushing block Filter Brake valve RTM module Wheel, travel motor

Hydraulic systems - Hydraulic systems

Interaxle differential lock ATC.

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RAIL14COM0386JA

2

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Hydraulic systems - Hydraulic schema SV216

NOTE: All numerical values on the schematics are metric.

Schematic guide Line color Red Blue Green Yellow

Description Operating pressure Return to tank Charge pressure Metered flow through restriction valve

INTER - Wheel differential lock Position 1 2 3 4 5 6

Designation Power-assisted steering valve Drum, travel motor Filler neck Thermoregulator Vibration motor Vibration pump

Position 7 8 9 10 11 12

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Designation Hydrostatic drive pump Flushing block Filter Brake valve Divider block Wheel, travel motor

Hydraulic systems - Hydraulic systems

INTER - Wheel differential lock

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RAIL14COM0393JA

1

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Interaxle differential lock ATC Position 1 2 3 4 5 6

Designation Power-assisted steering valve Drum, travel motor Filler neck Thermoregulator Vibration motor Vibration pump

Position 7 8 9 10 11 12

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Designation Hydrostatic drive pump Flushing block Filter Brake valve RTM module Wheel, travel motor

Hydraulic systems - Hydraulic systems

Interaxle differential lock ATC

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RAIL14COM0398JA

2

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Hydraulic systems - Test SV208 SV210

Test spots – Standard Position 1 2 3 4 5 6

Designation

Maximum pressure

Pressure in the reverse-travel circuit Pressure in the forward-travel circuit Pressure in the circuit for vibration I Pressure in the circuit for vibration II Pressure in the steering circuit Feed pressure

35 MPa (5077 psi)* 35 MPa (5077 psi)* 35 MPa (5077 psi) 35 MPa (5077 psi) 14 MPa (2031 psi)** 2.4 MPa (348 psi)***

* The value will increase by supplementary pressure, i.e. by up to 3 MPa (435 psi) ** Total pressure in the return steering line (supplementary pressure + flow losses) *** The value at idling speed (it is higher at maximum speeds). Maximum: 3 MPa (435 psi).

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SS13A843

1

SS13F139

2

Hydraulic systems - Hydraulic systems

Test spots – Option For easy diagnostics of hydraulic loops, the measuring pins are terminated in the panel and equipped with quick-couplers for easy and drip-proof connection of measuring devices.

Position 1 2 3 4 5 6

Designation

Maximum pressure

Pressure in the reverse-travel circuit Pressure in the forward-travel circuit Pressure in the circuit for vibration I Pressure in the circuit for vibration II Pressure in the steering circuit Feed pressure

35 MPa (5077 psi)* 35 MPa (5077 psi)* 35 MPa (5077 psi) 35 MPa (5077 psi) 14 MPa (2031 psi)** 2.4 MPa (348 psi)***

* The value will increase by supplementary pressure, i.e. by up to 3 MPa (435 psi) ** Total pressure in the return steering line (supplementary pressure + flow losses) *** The value at idling speed (it is higher at maximum speeds). Maximum: 3 MPa (435 psi).

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Hydraulic systems - Test SV212 SV216

Test-spots - Standard SV212 Position 1 2 5 6

Designation Pressure in the reverse-travel circuit Pressure in the forward-travel circuit Pressure in the steering circuit Feed pressure

Maximum pressure 42 MPa (6092 psi) * 42 MPa (6092 psi) * 19 MPa (2756 psi) ** 2.2 MPa (319 psi) ***

Designation Pressure in the reverse-travel circuit Pressure in the forward-travel circuit Pressure in the steering circuit Feed pressure

Maximum pressure 42 MPa (6092 psi) * 42 MPa (6092 psi) * 15 MPa (2176 psi) ** 2.2 MPa (319 psi) ***

SV216 Position 1 2 5 6

* The value will increase by supplementary pressure, i.e. by up to 3 MPa (435 psi) ** Total pressure in the return steering line (supplementary pressure + flow losses) *** The value at idling speed (it is higher at maximum speeds). Maximum: 3 MPa (435 psi).

Rexroth vibration pump Position 3 4

Designation Pressure in the circuit for vibration I Pressure in the circuit for vibration II

Maximum pressure 34 MPa (4932 psi) 34 MPa (4932 psi)

Sauer vibration pump Position 3 4

Designation Pressure in the circuit for vibration I Pressure in the circuit for vibration II

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Maximum pressure 35 MPa (5077 psi) 35 MPa (5077 psi)

Hydraulic systems - Hydraulic systems

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SS13F140

1

SS13F292

2

SS13F141

3

SS13F142

4

Hydraulic systems - Hydraulic systems

Test-spots - Option For easy diagnostics of hydraulic loops, the measuring pins are terminated in the panel and equipped with quick-couplers for easy and drip-proof connection of measuring devices.

SS13F143

Position 1 2 5 6

Designation Pressure in the reverse-travel circuit Pressure in the forward-travel circuit Pressure in the steering circuit Feed pressure

Maximum pressure 42 MPa (6092 psi) * 42 MPa (6092 psi) * 19 MPa (2756 psi) ** 2.2 MPa (319 psi) ***

* The value will increase by supplementary pressure, i.e. by up to 3 MPa (435 psi) ** Total pressure in the return steering line (supplementary pressure + flow losses) *** The value at idling speed (it is higher at maximum speeds). Maximum: 3 MPa (435 psi).

Rexroth vibration pump Position 3 4

Designation Pressure in the circuit for vibration I Pressure in the circuit for vibration II

Maximum pressure 34 MPa (4932 psi) 34 MPa (4932 psi)

Sauer vibration pump Position 3 4

Designation Pressure in the circuit for vibration I Pressure in the circuit for vibration II

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Maximum pressure 35 MPa (5077 psi) 35 MPa (5077 psi)

5

Index Hydraulic systems - 35 Hydraulic systems - 000 Hydraulic systems - Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic systems - Hydraulic schema (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic systems - Hydraulic schema (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Hydraulic systems - Hydraulic schema (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Hydraulic systems - Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Hydraulic systems - Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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

SV208 SV210 SV212 SV216

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

SERVICE Oil reservoir Change fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Oil filters Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Hydraulic systems - Reservoir, cooler, and filters

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. Attach a hose to the drain valve, loosen the valve, and drain the oil into a suitable container.

SS12K146

1

SS12K147

2

2. After the oil has completely drained, remove the hose and tighten the valve.

3. Remove the cover.

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4. Remove the cap on the filler neck on the top the tank.

NOTICE: Observe cleanliness during work. Avoid any contamination of the system with materials that might cause damage to critical units.

When cleaning the tank, use cleaners and lint-free rags.

Do not use chemical cleaners.

SS12K154

5. Add oil.

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3

Hydraulic systems - Reservoir, cooler, and filters

Oil filters - Replace 1. Detach the filter body using wrench (27).

SS13F125

1

SS13A829

2

SS13F126

3

SS13F127

4

2. Location of the hydraulic filter for rollers manufactured from 2007: SV208: from serial number 444 SV210: from serial number 127 SV212: from serial number 555 SV216: from serial number 430

3. Unscrew and remove the cover.

4. Drain the oil into a suitable container.

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Hydraulic systems - Reservoir, cooler, and filters

5. Remove the filter cartridge (17).

6. Replace the filter cartridge (17).

7. Check the condition of the sealing rings and lubricate them with oil.

8. Tighten the cover to 40 N·m (29.5 lb ft).

SS13F128

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5

Index Hydraulic systems - 35 Reservoir, cooler, and filters - 300 Oil filters - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Oil reservoir - Change fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Hydraulic systems - 35 Compaction/vibration hydraulic system - 995

SV208 SV210 SV212 SV216

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

TECHNICAL DATA Compaction/vibration hydraulic system Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Compaction/vibration hydraulic system Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Compaction/vibration hydraulic system Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Change fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Compaction/vibration hydraulic system - Technical Data SV 208 Drive type Low frequency High frequency High amplitude Low amplitude

SV 210

SV 212

SV 216

32 Hz 35 Hz 1.85 mm (0.073 in) 1.15 mm (0.045 in)

29 Hz 35 Hz 2 mm (0.079 in) 1 mm (0.039 in)

hydrostatic 30 Hz 41 Hz 1.7 mm (0.067 in) 1.85 mm (0.073 in) 0.86 mm (0.0339 in) 0.91 mm (0.0358 in)

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Compaction/vibration hydraulic system - Dynamic description The vibration hydraulic system is a closed loop, hydrostatic drive system that consists of a pump, a motor, and a shaft assembly. The pump sends oil to the motor, the motor spins the shaft, then the motor sends oil back to the pump. Engine speed and oil output from the pump determine the shaft speed, and this speed is preset at the factory.

Attempting to change the shaft speed by adjusting the pump is not recommended, but adjustments can be made to the pump if the machine is not operating as designed.

The pump is an axial piston, hydrostatic pump with the ability to vary the rate and the direction of the oil flow. The change of flow is accomplished by changing the position of the pump's swash plate (2). The angle of the swash plate (2) causes the pistons (1) to stroke in and out of the cylinder block bores as the swash plate (2) rotates.

Changing the angle of the swash plate (2) varies the piston stroke and the amount of oil being pumped to the motor. Tilting the swash plate (2) in the opposite direction reverses the flow to the motor which changes the direction of motor’s rotation.

RAIL14SSL0010BA

1

RAPH14SSL0332BA

2

RAPH14COM0407BA

3

The motor is a fixed displacement pump with axial pistons.

Inside the pump are a number of pistons (2) connected to a rotating cylinder block (3). The base of the pistons (2) sit diagonally on the fixed cam plate (1). When high pressure oil enters the pump, the piston (2) is at top dead center. The high pressure oil pushes the piston (2) and fills the cylinder. As oil fills the cylinder, the piston (2) descends the plane of the fixed cam plate (1), which spins the rotating cylinder block (3) and the output shaft. This process is called the reciprocation cycle. As the rotating cylinder block (3) continues to spin, the piston (2) ascends the plane of the fixed cam plate (1) and pushes oil out of the pump. This process is called the discharge cycle.

The vibrator is a shaft with two sets of eccentric weights (1) that create the vibration effect on the machine. This shaft assembly is designed to operate bidirectionally to achieve low or high frequencies for drum vibration. The vibration shaft is mounted to the inner pat of the drum and is attached vibration motor.

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During the high amplitude (1) rotation of the vibration shaft, the two eccentric weights are locked together which creates an extreme vibration by spinning one large mass of weight in one direction. During the low amplitude (2) rotation of the vibration shaft, the shaft is spun in the opposite direction. Spinning the shaft in the opposite direction disengages the locked weights and separates them. By separating the eccentric weights and dispersing the weight on the shaft, the rotating shaft creates less vibration.

RAIL14COM0515BA

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Hydraulic systems - Compaction/vibration hydraulic system

Compaction/vibration hydraulic system - Adjust SV208 SV210

WARNING Avoid injury!

Always turn OFF the engine before adjusting the vibration frequency.

Failure to comply could result in death or serious injury.

W1122A

NOTICE: Frequency measurement should be performed while the machine is running at maximum RPM with the engine warmed up to operating temperature and with hydraulic oil at a minimum temperature of 50 °C (122 °F).

Before setting the frequency, check and set the engine RPM according to the table and then set the revolution counter.

The engine should be warmed up to operating temperature while you are making engine settings.

NOTE: The RPM of engines are controlled by the ECM (electronic control module) of the engine. They are set by the manufacturer and it is not necessary to set them again.

1. Place the sensor (2) of the instrument (1) at the damping plate of the drum and measure the frequency.

NOTICE: If the frequency differs from that specified in this manual, adjust it by means of the adjusting screws on the vibration pump.

SS13F144

High amplitude Low amplitude

SV208 41 Hz 30 Hz

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SV210 41 Hz 30 Hz

1

Hydraulic systems - Compaction/vibration hydraulic system

2. The frequency of high amplitude vibration is adjusted by the lower screw (2) only. Undo the safety screw (3) and use a wrench to turn the set screw (2). Adjust to the required value and tighten the safety screw. Turning the screw counterclockwise increases frequency and clockwise decreases frequency.

NOTICE: The zero position of the power cylinder of the pump has been adjusted by the manufacturer on the upper screw (1). Any handling of this screw is not permitted.

The frequency meter may be ordered from your dealer.

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SS13F146

2

SS13F147

3

Hydraulic systems - Compaction/vibration hydraulic system

Compaction/vibration hydraulic system - Adjust SV212 SV216

WARNING Avoid injury!

Always turn OFF the engine before adjusting the vibration frequency.

Failure to comply could result in death or serious injury.

W1122A

NOTICE: Frequency measurement should be performed while the machine is running at maximum RPM with the engine warmed up to operating temperature and with hydraulic oil at a minimum temperature of 50 °C (122 °F).

Before setting the frequency, check and set the engine RPM according to the table and then set the revolution counter.

The engine should be warmed up to operating temperature while you are making engine settings.

NOTE: The RPM of engines are controlled by the ECM (electronic control module) of the engine. They are set by the manufacturer and it is not necessary to set them again.

1. Place the sensor (2) of the instrument (1) at the damping plate of the drum and measure the frequency.

NOTICE: If the frequency differs from that specified in this manual, adjust it by means of the adjusting screws on the vibration pump.

SS13F144

High amplitude Low amplitude

SV212 35 Hz 32 Hz

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SV216 35 Hz 29 Hz

1

Hydraulic systems - Compaction/vibration hydraulic system

2. Undo the lock nut (2) and use the screwdriver to turn the adjusting screw (1) – screwing out increases frequency and screwing in decreases frequency.

The upper screw (A) adjusts the frequency of the high amplitude.

The lower screw (B) adjusts the frequency of the low amplitude. Do not adjust to a higher frequency than that specified by the manufacturer. Do not switch the frequencies – the lower frequency must comply with the higher amplitude and vice versa. The manufacturer adjusts the lower frequency and the higher amplitude at the same direction as if the roller travels forward.

NOTICE: The zero position of the power cylinder of the pump has been adjusted by the manufacturer on the upper screw (1). Any handling of this screw is not permitted.

The frequency meter may be ordered from your dealer.

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SS13F145

2

SS13F147

3

Hydraulic systems - Compaction/vibration hydraulic system

Compaction/vibration hydraulic system - 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

NOTICE: Oil is best changed after roller operation, when the impurities are diffused within the medium.

1. Park the roller on a flat, paved area so that the drain plug (1) on the left-hand side of the drum is in its lowest position.

2. Place a suitable container underneath the plug.

3. Remove all the plugs and drain the oil.

4. Once drained, reinstall the drain plug (1).

5. Use the filler hole (2) to replenish the oil. Fill to the edge of the inspection hole (3).

6. Reinstall the remaining plugs.

SS12K145

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1

Index Hydraulic systems - 35 Compaction/vibration hydraulic system - 995 Compaction/vibration hydraulic system - Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Compaction/vibration hydraulic system - Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Compaction/vibration hydraulic system - Change fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Compaction/vibration hydraulic system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Compaction/vibration hydraulic system - Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. © 2014 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.

47688018 12/06/2014 EN

SERVICE MANUAL Frames and ballasting SV208 SV210 SV212 SV216

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39

Contents Frames and ballasting - 39

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

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Frames and ballasting - 39 Frame - 100

SV208 SV210 SV212 SV216

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Contents Frames and ballasting - 39 Frame - 100

FUNCTIONAL DATA Articulation frame pivot Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Articulation frame pivot Remove – Bearing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install – Bearing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Remove – Bearing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Install – Bearing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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Frames and ballasting - Frame

Articulation frame pivot - Component identification

SS13A729

1

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Frames and ballasting - Frame

Position 2 3 10 11 12 13 14 17 23 24 25 26 34

Designation Frame Hub Lower cover Top cover Pin Spreader Washer Packing piece Bearing Bearing Nut Locking sheet Bolt

Position 35 36 37 38 40 41 44 46 48 53 54 55 59

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Designation Bolt Bolt Bolt Bolt Bolt Bolt Washer Washer Spring washer Grease nipple Grease nipple Cap Scraper ring

Frames and ballasting - Frame

Articulation frame pivot - Remove – Bearing SV208 SV210

1. Park the machine on a firm surface and support the frame in the front and rear, using adequate lifting equipment.

SS13F024

1

SS13F025

2

SS13F150

3

SS13F151

4

2. Remove the packaging piece.

3. Using a suitable device, press the pins (1) out of the ends of the piston of the cylinder (6).

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Frames and ballasting - Frame

4. Remove the hose clamps on the drum frame.

SS13F152

5

SS13F026

6

SS13F028

7

SS13F029

8

5. Remove the hose clamps on the hinge and the rear frame.

6. Remove the hydraulic motor.

7. Slide the hydraulic motor from the drum and set aside.

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Frames and ballasting - Frame

8. Suspend the drum with the frame, using an adequate lifting device (4).

SS13F030

9

9. Remove the bolts (40).

SS13F153

10

SS13F031

11

SS13F299

12

10. Set the drum with front frame on the right side outside the machine.

11. Place suitable support equipment underneath.

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Frames and ballasting - Frame

12. Place the hoist under the frame plate (2).

13. Remove the bolts (37).

SS13F032

13

SS13F033

14

SS13F034

15

SS13F035

16

14. Move the plate (2) aside.

15. Undo the bolts (38).

16. Suspend the hub assembly with adequate lifting equipment (7), (6).

17. Set the bearing aside.

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Frames and ballasting - Frame

18. Undo the nut (25).

19. Remove the nut (25), using a wrench (8).

SS13F036

17

SS13F037

18

SS13F038

19

SS13F039

20

20. Remove the clamps of the pin.

21. Press the pins (12) out, using a jack.

22. Using adequate lifting equipment, set the hub assembly (3) aside.

23. Remove the covers (10) and (11) and the spacing pads (13).

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Frames and ballasting - Frame

24. Remove the bearings (24) from the hub, using a press.

SS13F040

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21

Frames and ballasting - Frame

Articulation frame pivot - Install – Bearing SV208 SV210

Prior operation: Order new bolts for the frame plate and the bearing on the frame plate.

1. Press the bearings (24) into the mount.

SS13F040

1

SS13F039

2

SS13F038

3

2. Install the covers (10) and (11) and the spacing pads (13).

3. Bring the two halves of the machine into position for the pin.

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Frames and ballasting - Frame

4. Install the pins (12), using a jack.

5. Install the clamps of the pin.

SS13F037

4

SS13F036

5

SS13F035

6

SS13F301

7

6. Install the nut. Torque the nut to 200.0 N·m (147.5 lb ft).

7. Bring the bearing into position.

8. Apply LOCTITE® 243 to the bolts.

NOTE: Install new bolts.

9. Torque the bolts to 117.0 N·m (86.3 lb ft).

NOTE: When torquing the bolts, please follow the order on image 7.

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Frames and ballasting - Frame

10. Carefully place the frame plate in position.

11. Apply LOCTITE® 243 to the bolts (38).

NOTE: Install new bolts.

SS13F032

8

SS13F337

9

12. Torque the bolts to 117.0 N·m (86.3 lb ft).

NOTE: When torquing the bolts, please follow the order on image 9.

13. Move the drum with front frame into the installation position.

SS13F031

10

SS13F153

11

14. Install the bolts (40).

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Frames and ballasting - Frame

15. Install the hydraulic motor.

SS13F028

12

SS13F026

13

SS13F152

14

SS13F151

15

16. Install the hose clamps on the hinge and the rear frame.

17. Install the hose clamps on the drum frame.

18. Press the pins (1) into the ends of the piston of the cylinder (6).

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Frames and ballasting - Frame

19. Install the packaging piece.

SS13F150

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16

Frames and ballasting - Frame

Articulation frame pivot - Remove – Bearing SV212 SV216

1. Park the machine on a firm surface and support the frame in the front and rear, using adequate lifting equipment.

SS13F024

1

SS13F025

2

SS13F150

3

SS13F151

4

2. Remove the packaging piece (17).

3. Using adequate equipment, press the pins (1) out of the ends of the pistons (6).

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Frames and ballasting - Frame

4. Remove the hose clamps on the drum frame.

SS13F152

5

SS13F026

6

SS13F027

7

SS13F028

8

5. Remove the hose clamps on the hinge and the rear frame.

6. Remove the vibration hydraulic motor cover.

7. Remove the vibration hydraulic motor.

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Frames and ballasting - Frame

8. Slide the hydraulic motor from the drum and set aside.

SS13F029

9

9. Suspend the drum with the frame, using an adequate lifting device (4).

NOTE: Use two twin hooks because of the weight.

SS13F030

10

SS13F153

11

SS13F031

12

10. Remove the bolts (40).

11. Set the drum with front frame on the right side of the machine.

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Frames and ballasting - Frame

12. Place adequate lifting equipment (5) underneath.

SS13F299

13

SS13F032

14

SS13F033

15

SS13F034

16

13. Place the hoist under the frame plate (2).

14. Remove the bolts (38).

15. Move the plate (2) aside.

16. Undo the bolts (38).

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Frames and ballasting - Frame

17. Suspend the hub assembly with adequate lifting equipment (7), (6).

18. Set the bearing aside.

SS13F035

17

SS13F036

18

SS13F037

19

SS13F038

20

19. Undo the nut (25).

20. Remove the nut (25), using wrench (8).

21. Remove the clamps of the pin.

22. Press the pins (12) out.

23. Carefully remove the hub assembly (3), using adequate lifting equipment.

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Frames and ballasting - Frame

24. Remove the covers (10) and (11) and the spacing pads (13).

SS13F039

21

SS13F040

22

25. Remove the bearings (24) from the hub, using a press.

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Frames and ballasting - Frame

Articulation frame pivot - Install – Bearing SV212 SV216

Prior operation: Order new bolts for the frame plate and the bearing on the frame plate.

1. Press the bearings (24) into the mount.

SS13F040

1

SS13F039

2

SS13F038

3

2. Install the covers (10) and (11) and the spacing pads (13).

3. Bring the two halves of the machine into position for the pin.

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Frames and ballasting - Frame

4. Install the pins (12), using a jack.

5. Install the clamps of the pin.

SS13F037

4

SS13F036

5

SS13F035

6

SS13F301

7

6. Install the nut. Torque the nut to . 260.0 N·m (191.8 lb ft).

7. Bring the bearing into position.

8. Apply LOCTITE® 243 to the bolts.

NOTE: Install new bolts.

9. Torque the bolts to 184.0 N·m (135.7 lb ft).

NOTE: When torquing the bolts, please follow the order on image 7.

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Frames and ballasting - Frame

10. Carefully place the frame plate in position.

11. Apply LOCTITE® 243 to the bolts (38).

NOTE: Install new bolts.

SS13F032

8

SS13F337

9

12. Torque the bolts to 184.0 N·m (135.7 lb ft).

NOTE: When torquing the bolts, please follow the order on image 9.

13. Move the drum with front frame into the installation position.

SS13F031

10

SS13F153

11

14. Install the bolts (40).

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Frames and ballasting - Frame

15. Install the hydraulic motor.

SS13F028

12

SS13F027

13

SS13F026

14

SS13F152

15

16. Install the vibration hydraulic motor cover.

17. Install the hose clamps on the hinge and the rear frame.

18. Install the hose clamps on the drum frame.

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Frames and ballasting - Frame

19. Press the pins (1) into the ends of the piston of the cylinder (6).

SS13F151

16

SS13F150

17

20. Install the packaging piece.

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Index Frames and ballasting - 39 Frame - 100 Articulation frame pivot - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Articulation frame pivot - Install – Bearing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Articulation frame pivot - Install – Bearing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Articulation frame pivot - Remove – Bearing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Articulation frame pivot - Remove – Bearing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

(*) See content for specific models 47688018 12/06/2014

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Frames and ballasting - 39 Vibratory roller - 500

SV208 SV210 SV212 SV216

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Contents Frames and ballasting - 39 Vibratory roller - 500

FUNCTIONAL DATA Vibratory drum mounts Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Vibratory drum mounts Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

(*) See content for specific models 47688018 12/06/2014

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Frames and ballasting - Vibratory roller

Vibratory drum mounts - Component identification SV208 SV210

SS13G159

Position 1 2 3 4 5 6 7 8 9

Designation Bracket Not used Carrier Cover Not used Drive motor Gear reduction assembly Not used Not used

1

Position 10 11 12 13 14 15 16 17 18 19

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Designation Not used Bolt Bolt Bolt Not used Nut Not used Washer Not used Washer

Frames and ballasting - Vibratory roller

Vibratory drum mounts - Component identification SV212 SV216

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Frames and ballasting - Vibratory roller

SS13A726

1

Motor mount

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Frames and ballasting - Vibratory roller

Motor mount table Position 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Designation Bracket Yoke Not used Carrier Cover Not used Not used Gear reduction assembly Not used Not used Bolt Bolt Bolt Bolt Bolt

Position 16 17 18 19 20 21 22 23 24 25 26 27 28 29

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Designation Bolt Bolt Bolt Bolt Not used Not used Nut Nut Nut Not used Not used Washer Washer Washer

Frames and ballasting - Vibratory roller

SS13A722

2

Mount

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Frames and ballasting - Vibratory roller

Mount table Position 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Designation Damper plate Not used Bracket Plate Bracket Yoke Weight Not used Not used Drive motor Not used Not used Ring Not used Not used Ring Ring Not used Bleeder valve Packing ring Not used v Nut Locking sheet Not used

Position 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

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Designation Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Not used Not used Nut Nut Nut Nut Not used Not used Washer Washer Washer Washer Not used Not used Spring washer Spring washer

Frames and ballasting - Vibratory roller

Vibratory drum mounts - Disassemble SV208 SV210

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

1. Remove the bracket from the drum together with the vibrator plate.

2. Remove the bolts (1).

SS13A532

1

SS13A533

2

SS13A534

3

3. Remove the bolts (45) and remove the bracket (2) from the rubberized metal pieces.

4. Rotate the vibrator plate and place it on the rubber mounting.

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Frames and ballasting - Vibratory roller

5. Remove the safety pad (31).

SS13A535

4

SS13A536

5

SS13A537

6

SS13A538

7

6. Place the spanner socket (3) on the nut (30).

7. Remove the nut (30) and the pad (31).

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Frames and ballasting - Vibratory roller

8. Turn the vibrator plate (3) with the hub (9) upside down.

9. Support it.

SS13A701

8

SS13A702

9

10. Remove the bolts (42).

11. Insert the bolts in the hole, and remove the hub (9) by tightening in steps. If necessary, use a bolt (4).

SS13A703

10

SS13A704

11

12. Press out the bearing (28) from the hub, seal ring (22), and collar (23).

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Frames and ballasting - Vibratory roller

Vibratory drum mounts - Assemble SV208 SV210

1. Press the outer ring out of the bearing (28).

2. Turn and press the outer ring of the bearing.

3. Install the seal ring (22) using an adequate seal installer.

SS13A705

1

SS13A706

2

SS13A707

3

SS13A708

4

4. Preheat ring (13) to 90 °C (194 °F). On the vibrator plate bearing, install the O-ring (26) and the ring (13).

5. Preheat bearing (28) to 90 - 110 °C (194 - 230 °F). Insert the inner part of the bearing (28).

6. Fill the bearings with grease.

7. Insert the hub (9).

8. Preheat bearing (28) to 90 - 110 °C (194 - 230 °F). Insert the inner part of the bearing (28).

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Frames and ballasting - Vibratory roller

9. Insert the pad (31) and the nut (30).

SS13A538

5

SS13A709

6

SS13A710

7

10. Tighten the nut with an adequate socket (3).

NOTE: Tap on the socket (3) while tightening.

11. Torque the nut to 70.0 - 80.0 N·m (51.6 - 59.0 lb ft).

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Frames and ballasting - Vibratory roller

Vibratory drum mounts - Disassemble SV212 SV216

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

1. Turn the vibration plate and place it on the metal rubber parts.

SS13A534

1

SS13F193

2

SS13A536

3

2. Unlock the retaining washer (24).

3. Mount the spanner socket (3) on the nut (23).

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Frames and ballasting - Vibratory roller

4. Dismount the nut (23) and the washer (24).

SS13A537

4

SS13F194

5

SS13F195

6

SS13F214

7

5. Turn the vibration plate (1) with the hub pointing downwards.

6. Dismount the bolts (30).

7. Insert bolts (4) into the holes, and dismount the hub by means of gradual tightening the bolts (4). If it is necessary, use a clamp.

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Frames and ballasting - Vibratory roller

8. Strike out the bearings (28), the rubber seal (22), and the ring (23) from the hub.

SS13A704

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8

Frames and ballasting - Vibratory roller

Vibratory drum mounts - Assemble SV212 SV216

1. Press on the outer ring of the bearing (28).

2. Turn and mount the outer ring of the other bearing.

3. Press on the rubber seal (22) by using an adequate seal installer.

SS13A705

1

SS13F196

2

SS13A707

3

SS13A708

4

4. Preheat ring (13) to 90 °C (194 °F). Mount the O-ring (17) and the ring (13). .

5. Preheat bearing (28) to 90 - 110 °C (194 - 230 °F).

Mount the inner part of the bearing (28).

6. Fill the bearings with lubricating grease.

7. Mount the hub (9).

8. Preheat bearing (28) to 90 - 110 °C (194 - 230 °F).

Mount the inner part of bearing (28).

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Frames and ballasting - Vibratory roller

9. Mount the washer (24) and the nut (23).

SS13F194

5

SS13F215

6

SS13F216

7

10. Tighten the nut, using a spanner socket (3).

11. Torque the nut to 75 - 80 N·m (55.3 - 59 lb ft).

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Index Frames and ballasting - 39 Vibratory roller - 500 Vibratory drum mounts - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Vibratory drum mounts - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Vibratory drum mounts - Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Vibratory drum mounts - Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Vibratory drum mounts - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Vibratory drum mounts - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

(*) See content for specific models 47688018 12/06/2014

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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. © 2014 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.

47688018 12/06/2014 EN

SERVICE MANUAL Steering SV208 SV210 SV212 SV216

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41

Contents Steering - 41

[41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1

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Steering - 41 Cylinders - 216

SV208 SV210 SV212 SV216

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Contents Steering - 41 Cylinders - 216

TECHNICAL DATA Steering cylinder Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Steering - Cylinders

Steering cylinder - Torque SV208 and SV210 - Steering cylinder 80/40-360

M 30x2

Connection of piston rod Thread Tightening torque 130.0 N·m (95.9 lb ft)

Connection of cylinder body, cover Thread Tightening torque M85x1.5 180.0 N·m (132.8 lb ft)

SV212 and SV216 - Steering cylinder 90/45-400

M 32x2

Connection of piston rod Thread Tightening torque 140.0 N·m (103.3 lb ft)

Connection of cylinder body, cover Thread Tightening torque M95x1.5 200.0 N·m (147.5 lb ft)

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Index Steering - 41 Cylinders - 216 Steering cylinder - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. © 2014 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.

47688018 12/06/2014 EN

SERVICE MANUAL Wheels SV208 SV210 SV212 SV216

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Contents Wheels - 44

[44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1 [44.160] Compaction drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2

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Wheels - 44 Rear wheels - 520

SV208 SV210 SV212 SV216

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Contents Wheels - 44 Rear wheels - 520

TECHNICAL DATA Rear wheels Tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Rear wheels Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Wheels - Rear wheels

Rear wheels - Tire pressure 100% air • SV 208 and SV 210: 150 kPa (21.8 psi) • SV 212 and SV 216: 160 kPa (23.2 psi) 75% liquid solution, 25% air • SV 208 and SV 210: 150 kPa (21.8 psi) • SV 212 and SV 216: 160 kPa (23.2 psi)

Rear wheels - Capacities Filling tires with water up to 0 °C (32 °F) Filling tires with water for SV 208 and SV 210 up to 0 °C (32 °F) Water 180.0 l (47.6 US gal)

Anticorit SKR 40 3.5 kg (7.7 lb)

Added weight 183.5 kg (404.5 lb)

Filling tires with water for SV 212 and SV 216 up to 0 °C (32 °F) Water 500.0 l (132.1 US gal)

Anticorit SKR 40 10 kg (22 lb)

Added weight 510.0 kg (1124.4 lb)

Filling tires with water up to -25 °C (-13 °F) The inner space of the tire is filled with a solution of water and 34 % calcium chloride CaCl2.

Filling tires with water for SV 208 and SV 210 up to -25 °C (-13 °F) Water 65.0 l (17.2 US gal)

34 % Calcium chloride CaCI2 145.2 kg (320.1 lb)

Added weight 210 kg (463 lb)

Filling tires with water for SV 212 and SV 216 up to -25 °C (-13 °F) Water 185.0 l (48.9 US gal)

34 % Calcium chloride CaCI2 414.7 kg (914.3 lb)

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Added weight 600 kg (1323 lb)

Wheels - Rear wheels

Rear wheels - Remove 1. Hoist the rear frame of the machine and insert a support.

SS13F100

1

SS13F121

2

SS13F122

3

2. Remove the bolts (8) and the washers (11).

3. Remove the tire with the disk and move it aside, using adequate lifting equipment (1).

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Wheels - Rear wheels

Rear wheels - Install 1. Mount the tire on the hub.

SS13F123

1

SS13F121

2

2. Install the tire with the disk supplied in the set with the tamping drum. Tighten to torque – refer to Torque ().

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Wheels - Rear wheels

Rear wheels - Filling WARNING Pressurized fluid can penetrate the skin and cause severe injuries.

The solution can spurt out after unscrewing the valve insert.

Failure to comply could result in death or serious injury.

W1118A

WARNING Avoid injury!

Use Personal Protective Equipment (PPE), including protective goggles, gloves, and safety footwear.

Failure to comply could result in death or serious injury.

W1036A

WARNING Hazardous chemicals!

SLOWLY add calcium chloride flakes to water, stirring continuously. To avoid a violent reaction, NEVER add water to calcium chloride.

If any flakes contact the eyes, flush the eyes immediately with clean, cold water for at least 15 minutes.

Seek medical assistance immediately.

Failure to comply could result in death or serious injury.

W0388A

1. Move the machine to a firm surface. The filling valves should be in the extreme upper position.

2. Secure the drum with chocks on both sides.

3. Unscrew the removable valve insert and install the filler neck.

SS13A881

1

SS13A880

2

4. Mount the hose from the filling equipment on the filler neck, and fill the tires with the solution.

5. During the filling, air escapes from the tire through the side opening on the filler neck. The tire is sufficiently filled when the solution starts flowing through the opening or when the tire is 75 % filled with solution.

6. Unscrew the filler neck.

7. Install the valve insert, and inflate the tire to a pressure of: • SV 208 and SV 210: 150 kPa (21.8 psi) • SV 212 and SV 216: 160 kPa (23.2 psi) 47688018 12/06/2014

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Index Wheels - 44 Rear wheels - 520 Rear wheels - Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Rear wheels - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Rear wheels - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Rear wheels - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Rear wheels - Tire pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Wheels - 44 Compaction drums - 160

SV208 SV210 SV212 SV216

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Contents Wheels - 44 Compaction drums - 160

FUNCTIONAL DATA Compaction front drum Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Component identification - Pad foot (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Component identification - Pad foot (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Compaction front drum shaft Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

SERVICE Compaction front drum Change fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Remove – Pad foot segments (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Install – Pad foot segments (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Remove – Pad foot segments (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Install – Pad foot segments (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Compaction front drum shaft Disassemble – Vibrator (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Assemble – Vibrator (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Disassemble – Vibrator (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Assemble – Vibrator (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

(*) See content for specific models 47688018 12/06/2014

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Wheels - Compaction drums

Compaction front drum - Component identification SV208 SV210

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Wheels - Compaction drums

SS13A720

Position 1 Drum 2 Bracket

Designation

1

Position 28 Bearing 30 Nut 47688018 12/06/2014

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Designation

Wheels - Compaction drums

Position 3 4 7 8 9 12 13 15 16 17 19 22 23 24 25 26 27

Designation Vibrator plate Oil dippers Left cover Right cover Hub Cover Ring Spacing ring Spacing ring Bolt Washer Seal ring Collar Ring Ring Ring Ring

Position 31 33 35 38 39 42 44 45 46 48 52 54 56 57 59 62 64

SS13G158

Position 1 2 10 13 14

Designation Frame Front plate Plug Hexagon head bolt Hexagon head bolt

Designation Safety pad Magnetic plug Hydraulic motor Bolt Bolt Bolt Bolt Bolt Bolt Bolt Nut Washer Spring washer Washer Washer Bleeder valve Packing ring

2

Position 15 16 20 24

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Designation Hexagon head bolt Hexagon head bolt Hexagon nut Spring washer

Wheels - Compaction drums

Compaction front drum - Component identification SV212 SV216

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Wheels - Compaction drums

SS13A721

Position Designation 1 Smooth drum 4 Oil dippers

1

Position 25 Ring 28 Bearing 47688018 12/06/2014

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Designation

Wheels - Compaction drums

Position 7 8 9 10 12 17 18 19 22 23 24

Designation Left cover Right cover Hub Cover Cover Washer Washer Washer Rubber seal Ring Ring

Position 33 38 39 40 46 47 48 56 57 59

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Designation Magnetic plug Bolt Bolt Bolt Bolt Bolt Bolt Spring washer Washer Washer

Wheels - Compaction drums

Compaction front drum - Component identification - Pad foot SV208 SV210

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Wheels - Compaction drums

SS13A840

1

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Wheels - Compaction drums

Position 1 2 5 6 7 11 12

Designation Segment Clamp Plate Rear scraper Front scraper Bolt Bolt

Position 16 20 21 22 25 26 27

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Designation Nut Spring washer Washer Washer Nut Nut Bolt

Wheels - Compaction drums

SS13G157

Position 1 Rest 2 Bolt

Designation

2

Position 3 Yoke

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Designation

Wheels - Compaction drums

Compaction front drum - Component identification - Pad foot SV212 SV216

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Wheels - Compaction drums

SS13F305

Position.

1 Segment 2 Scrapers

Designation

1

Position .

13 Nut 16 Washer 47688018 12/06/2014

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Designation

Wheels - Compaction drums

Position.

5 Clamp 9 Bolt 10 Bolt

Designation

Position .

17 Washer 18 Washer

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Designation

Wheels - Compaction drums

SS13G157

Position .

1 Rest 2 Bolt

Designation

2

Position .

3 Yoke

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Designation

Wheels - Compaction drums

Compaction front drum shaft - Component identification SV208 SV210

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Wheels - Compaction drums

SS13A724

Position 1 Cam body 2 Cam

Designation

1

Position 8 Bushing 11 Key 47688018 12/06/2014

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Designation

Wheels - Compaction drums

Position 3 4 5 6 7

Designation Free eccentric Free eccentric Shaft Coupling Ring

Position 12 13 15 19

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Designation Key Insert Locking ring Bearing

Wheels - Compaction drums

Compaction front drum shaft - Component identification SV212 SV216

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Wheels - Compaction drums

SS13A723

Position Designation 1 Fixed eccentric 2 Free eccentric

1

Position 9 Ring 10 Bush 47688018 12/06/2014

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Designation

Wheels - Compaction drums

Position 3 4 5 6 7 8

Designation Fixed eccentric Free eccentric Left shaft Right shaft Shaft Coupling

Position 14 16 17 20 21

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Designation Bearing Locking ring Locking ring Key Pin

Wheels - Compaction drums

Compaction front drum - Change fluid SV212 SV216

The drum fluid lasts the entire service life of the drum and does not require changing. The lower plug is used for draining the fluid and the upper plug is for filling up and checking the fluid level. When draining the fluid, verify that the drum is in an inclined position for draining. After the drum has been filled up, move the machine so that the plugs are at the opposite position (upward).

NOTICE: Do not operate the machine without filling the drum with water.

SS12K173

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1

Wheels - Compaction drums

Compaction front drum - Remove SV208 SV210

1. Lift the drum frame until the drum just touches the ground.

2. Support on both sides firmly with adequate lifting equipment.

SS13A506

1

SS13A507

2

SS13A508

3

SS13A509

4

3. Remove the hydraulic motor cover.

4. Remove the holders for the hoses on the vibration hydraulic motor.

5. Unscrew the four bolts from the vibration hydraulic motor.

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Wheels - Compaction drums

6. Remove the hydraulic motor and set it aside on the side of the frame.

SS13A510

5

SS13A511

6

SS13A512

7

SS13A513

8

7. Remove the hose holders on the rear cross member of the frame.

8. Remove the hose holders of the travel hydraulic motor.

9. Place a catch basin underneath the travel hydraulic motor.

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Wheels - Compaction drums

10. Remove the travel hydraulic motor hoses.

SS13A514

9

11. Plug the outlets of hoses and the hydraulic motor.

SS13A515

10

SS13A516

11

SS13A517

12

12. Tie the hoses to the mirror on the cab.

13. Disconnect the wires from the travel hydraulic motor (sensor, solenoid).

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Wheels - Compaction drums

14. Unscrew the plug in the front cross member (8).

15. Install the hooks.

SS13A518

13

SS13A519

14

SS13A520

15

SS13A521

16

16. Suspend the cross member, using adequate lifting equipment.

17. Remove the bolts (13) on both sides.

18. Set the cross member aside.

19. Undo the connecting bolts of the frame with the bracket on the left side and (13) on the right side.

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Wheels - Compaction drums

20. Slide the rubber mounting off, using bolts (1).

SS13A522

17

SS13A524

18

SS13A525

19

SS13A526

20

21. Remove the spacers, after removing the bolts that connect the frame of the drum.

22. Roll the drum out from the frame.

23. Carefully rotate the drum until the drain plug in the left cover is in the lower position.

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Wheels - Compaction drums

24. Use proper chocks to prevent movement.

SS13A527

21

SS13A526

22

25. Unscrew the drain plug from the cover of the vibrator.

26. Drain oil to the catch basin.

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Wheels - Compaction drums

Compaction front drum - Install SV208 SV210

1. Install the drain plug into the cover of the vibrator.

SS13A526

1

SS13A525

2

SS13A524

3

SS13A522

4

2. Roll the drum into the frame.

3. Install the spacers.

4. Slide the rubber mounting on.

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Wheels - Compaction drums

5. Torque the rubber mounting to 8.0 - 10.0 mm (0.3 0.4 in).

SS13A523

5

SS13A521

6

SS13A520

7

SS13A517

8

6. Install the connecting bolts of the frame with the bracket on the left side and (13) on the right side.

7. Install the cross member.

8. Connect the wires to the travel hydraulic motor (sensor, solenoid).

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Wheels - Compaction drums

9. Install the travel hydraulic motor hoses.

SS13A514

9

10. Install the hose holders on the rear cross member of the frame.

SS13A511

10

SS13A509

11

SS13A508

12

11. Install the four bolts for the vibration hydraulic motor.

12. Install the holders of the vibration hydraulic motor hoses.

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Wheels - Compaction drums

13. Install the hydraulic motor cover.

SS13A507

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13

Wheels - Compaction drums

Compaction front drum - Remove SV212 SV216

1. Jack up the drum frame so that the drum touches the ground lightly.

2. Place it on fixed supports on both sides.

SS13F176

1

SS13A513

2

SS13F177

3

Left side 3. Put a drain pan under the vibration hydraulic motor.

4. Dismount the vibration hydraulic motor hoses.

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Wheels - Compaction drums

5. Plug the hose and hydraulic motor outlets.

SS13F178

4

SS13F179

5

SS13F180

6

SS13A513

7

6. Dismount the vibration hydraulic motor hoses collars.

7. Fasten the hoses to the can using bands.

Right side 8. Put a drain pan under the travel hydraulic motor.

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Wheels - Compaction drums

9. Dismount the cover of the travel hydraulic motor.

SS13F213

8

SS13A514

9

10. Dismount the travel hydraulic motor hoses.

11. Plug the hose outlets.

SS13A515

10

SS13F181

11

12. Disconnect the electrical installation from the travel hydraulic motor.

13. Plug the outlets.

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Wheels - Compaction drums

14. Fasten the hoses behind the mirror arm to the cab.

SS13A516

12

SS13F182

13

SS13F183

14

SS13F184

15

15. Dismount the bolts (33) from the weights on the left side of the front frame.

16. Dismount the bolts (19) of the bracket on the right side of the front frame.

17. Slacken the bolts and push the weights into the drum so that there is a gap between the weight and the machine frame.

18. Tighten the bolts.

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Wheels - Compaction drums

19. Using adequate lifting equipment, hang the drum, and carefully move it away from the frame.

SS13F185

16

SS13A526

17

SS13F186

18

SS13F187

19

20. Set the drum so that the drain plug is on the left cover in the lower position.

21. Secure it against accidental movement by means of blocks.

22. Unscrew the drain plug from the vibrator cover and drain the oil to the drain container.

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Wheels - Compaction drums

23. Hang the weight, using adequate lifting equipment.

24. Lift up.

25. Unscrew the bolts.

26. Push from the drum and remove.

SS13F188

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20

Wheels - Compaction drums

Compaction front drum - Install SV212 SV216

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

1. Place the frame on suitable supports on both sides.

Hang the drum and lift it by using adequate lifting equipment, and mount it into the frame so that the drum does not bump into the frame.

SS13F206

1

SS13F207

2

SS13F208

3

2. Make sure that there is a gap of 22.0 - 26.0 mm (0.9 1.0 in) between the frame and the drum on both sides.

3. Screw the bracket on the right side to the frame. If it is necessary, use shims.

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4. Slacken the bolts on the left side of the drum.

SS13F209

4

SS13F210

5

SS13F211

6

SS13F212

7

5. Mount the weight to the frame and then retighten it by means of bolts.

6. Using a square, measure the distance between the drum and frame near the joint at various places (refer to figure 6). The drum must be axially centred.

7. Lift up the drum and remove the supports.

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Compaction front drum - Remove – Pad foot segments SV208 SV210

1. Remove the segment scrapers.

SS13F098

1

SS13F303

2

SS13F089

3

SS13F090

4

2. Roll the first segment into a safe position for lifting.

3. Install eight clamps (four per side, and two per pad foot) onto the pad foot and drum.

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4. Remove the bolts that connect the segments.

SS13F097

5

SS13F087

6

SS13F093

7

SS13F088

8

5. Suspend the first segment behind the opening in the lug.

6. Remove the clamps on the first segment.

7. Remove the first segment.

8. Repeat this procedure on the other pad foot.

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Compaction front drum - Install – Pad foot segments SV208 SV210

1. Place the machine on a firm and flat ground.

SS13F079

1

SS13F080

2

SS13F081

3

2. Suspend the front scraper with clamps for smooth drums, using adequate lifting equipment.

3. Remove the scraper bolts.

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4. Lower the scraper to the ground and set them aside.

SS13F082

4

SS13F083

5

SS13F084

6

SS13F085

7

5. Follow the same procedure for the removal of the rear scraper.

6. Remove the plugs in the drum frame.

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7. Clean thoroughly the surface of the drum.

SS13F086

8

SS13F087

9

8. Suspend the first segment behind the opening in the lug.

9. Place it on the drum.

SS13F088

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10

Wheels - Compaction drums

10. Even up segment edges with the edge of the drum.

11. Fasten with four clamps (two on each side).

SS13F089

11

SS13F090

12

SS13F088

13

SS13F097

14

12. Drive slowly forward for about 1.60 m (5.25 ft).

NOTE: While checking the clamps so that they wouldn’t interfere with the drum frame.

13. Situate the second segment to create a space (X) of about 26.00 mm (1.02 in) between the segments.

14. Connect segments using material (12), (16), (21), and (22), refer to Compaction front drum - Component identification - Pad foot (44.160).

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15. Move forward again, set up the third segment and proceed as before with the second segment.

SS13F303

15

SS13F304

16

SS13F098

17

SS13F099

18

16. The second nut is a thread protection only. The bolt must overhang approximately 6.00 mm (1/4 in) (X).

Distribute the overhang evenly on all of the bolts on the circumference of the drum.

17. Install the segment scrapers supplied with the segments on the front beam and the rear cross beam of the drum frame.

18. Adjust gap between scraper and the drum to 30.00 mm (1 1/8 in).

19. You may use for installation also previously removed bolts and pads.

20. Tighten to torque. Refer to Torque ().

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After installation 21. With the bolted joints tightened as specified in the torques table, operate the machine with low or high vibration switched ON and with travel speed 1 set for 2 min.

22. Stop the machine and confirm that bolted joints are tightened to the torque specified in the table.

23. Operate the machine for a minimum of 1 h, adjusting travel speed within 1-3 range.

24. Recheck that bolted joints are tightened.

SS13F149

Model SV208 and SV210

Bolt M16 8G

19

Tightening 200.0 N·m (147.5 lb ft)

NOTICE: Continually check the bolted joints during machine operation.

When operating the roller in the above-mentioned process, never use high or low vibration frequency on the surface already being compacted, a hard subsurface or a frozen surface.

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Compaction front drum - Remove – Pad foot segments SV212 SV216

1. Remove the scrapers (2).

SS13F096

1

SS13F303

2

SS13F093

3

SS13F090

4

2. Roll the first segment into a safe position for lifting.

3. Install eight clamps (four per side, and two per pad foot) onto the pad foot and drum.

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4. Remove the bolts that connect the segments.

SS13F097

5

SS13F087

6

SS13F093

7

SS13F088

8

5. Suspend the first segment behind the opening in the lug.

6. Remove the clamps on the first segment.

7. Remove the first segment.

8. Repeat this procedure on the other pad foot.

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Compaction front drum - Install – Pad foot segments SV212 SV216

1. Place the machine on a firm and flat ground.

SS13F079

1

SS13F086

2

SS13F091

3

2. Clean thoroughly the surface of the drum.

First segment 3. Suspend the first segment across the openings in the lugs on both sides of the machine.

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4. Place it on the drum.

SS13F092

4

SS13F093

5

SS13F090

6

SS13F094

7

5. Even up segment edges with the edge of the drum.

6. Use four clamps to fix on each side.

Second segment 7. Drive the Machine slowly forward by about 2.40 m (7.87 ft).

NOTICE: While checking the clamps so that they wouldn’t interfere with the drum frame.

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8. Suspend the second segment across the openings in the lugs in the same way as the first segment.

9. Position the second segment so that there is a gap between the segment ends (X) of about 26.00 mm (1.02 in).

10. Connect segments using material (10), (13), and (16), refer to Compaction front drum - Component identification - Pad foot (44.160).

SS13F095

8

SS13F093

9

11. Dismount the clamps on both sides of the machine.

12. The second nuts are used to cover the thread.

13. Distribute the overlap evenly within 6.00 mm (0.24 in) range.

SS13F304

10

SS13F096

11

14. Mount the scrapers (2) by washers (17), (18), and bolts (9) from both sides of the frame.

15. Check out whether the segment lugs fits into the holes between the scrapers.

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Wheels - Compaction drums

After installation 16. With the bolted joints tightened as specified in the torques table, operate the machine with low or high vibration switched ON and with travel speed 1 set for 2 min.

17. Stop the machine and confirm that bolted joints are tightened to the torque specified in the table.

18. Operate the machine for a minimum of 1 h, adjusting travel speed within 1-3 range.

19. Recheck that bolted joints are tightened.

SS13F149

Model SV212 and SV216

Bolt M20 8G

12

Tightening torque 390.0 N·m (287.6 lb ft)

NOTICE: Continually check the bolted joints during machine operation.

When operating the roller in the above-mentioned process, never use high or low vibration frequency on the surface already being compacted, a hard subsurface or a frozen surface.

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Compaction front drum shaft - Disassemble – Vibrator SV208 SV210

CAUTION Heavy object!

The component is heavy. Use care not to drop the component when installing, removing, or handling.

Failure to comply could result in minor or moderate injury.

C0095A

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

NOTICE: In the twin version (left and right vibrator), the two vibrators are mounted on the same shaft. For the reason of higher weight, the vibration exciter is installed in the vertical position of the drum from the left side.

When replacing the bearing of the right lid, it is necessary to place the drum with its left side down by means of two clamps.

1. Before removing the vibrator, position the drum vertically with its right side down. Remove the left cover and pull the vibrator out of the drum using adequate lifting equipment (extender for suspension eyelet).

2. Design of the vibrator.

SS13A714

1

SS13A716

2

3. Remove the half-segments of the rings (7) and the loose cam (2). The rigid cam may be removed by milling the cam body (1) in its weakest point, or use a new shaft (5) with a cam (1).

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4. If new parts are used in mounting the vibrator, warm up the center (1) to 250 - 350 °C (482 - 662 °F), and place it on a jig pad (9), and insert in it the shaft (5) with the key (11).

SS13A717

3

SS13A718

4

SS13A719

5

5. Press the bushing (8) into the cam (2) using adequate pressing equipment.

6. Calibrate the bushing using an adequate calibration tool (10).

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Compaction front drum shaft - Assemble – Vibrator SV208 SV210

CAUTION Heavy object!

The component is heavy. Use care not to drop the component when installing, removing, or handling.

Failure to comply could result in minor or moderate injury.

C0095A

NOTICE: Install the right lid with the bearing, position the drum vertically using clamps (7), (8), and install the vibrator.

When the vibration exciter is in place, check the axial free play of the bearings of the exciter (refer to image 1).

1. For installing the outer rings of the bearings (19) to the covers (7) and (8), follow pairing with internal bearing rings.

SS13F338

1

SS13F021

2

SS13F022

3

2. After having installed the covers (7) and (8), check the axial bearing play using an adequate tool (11). The axial bearing play for both vibrators must be 1.5 - 2.5 mm (0.06 - 0.10 in).

3. When replacing the vibration hydraulic motors (35), heat the hub to 200 °C (392 °F) and slide on the output shaft of the hydraulic motor. The guide pin on the spline must move freely to full stop and must not be forced.

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4. Use Loctite-577 to secure the bolts (17) of the hydraulic motor (35).

5. Install the bolts for the vibration hydraulic motor, and torque the bolts to 160 N·m (118 lb ft).

SS13F023

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4

Wheels - Compaction drums

Compaction front drum shaft - Disassemble – Vibrator SV212 SV216

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

1. Dismount the bolts (38).

2. Hang the cover (8) on an adequate lifting device (13).

3. Use three bolts (M16) in the process openings (A).

4. Push the cover away from the drum face.

5. Remove the cover (8).

SS13F217

1

SS13F218

2

SS13F219

3

6. Remove the vibrator, using an adequate lifting device (13).

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7. Dismount the bolts (40).

8. Remove the cover (10).

9. Dismount the locking ring (16).

10. Press out the bearing outer rings from the covers (8) and (10).

11. Dismount the connecting shaft (7).

SS13F198

4

SS13A715

5

SS13F199

6

SS13F200

7

12. When dismounting the covers (7) and (10) and the vibrator on the left side of the drum, follow the same procedure.

13. Preheat the bearing inner rings (14) to 90 - 110 °C (194 - 230 °F) and dismount them from the shafts.

14. Dismount the bearing inner rings (14) from the shafts.

15. Remove the ring halves (9) and dismount the free cam (2). The fixed cam (1) can be removed by cutting the cam body at its thinnest point; this is not necessary if you are going to use a new shaft (5) and (6) with cam (1) for reassembly.

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Compaction front drum shaft - Assemble – Vibrator SV212 SV216

1. If new parts are used when mounting the vibrator, heat the cam (1) to a temperature of 250 - 350 °C (482 662 °F), and place it on a jig support (9). Push the shafts (5), (6) with a key (20) into the cam (1).

SS13F201

1

SS13F202

2

SS13F220

3

SS13F203

4

2. Press the bushing (10) into the cam (2), using an adequate installer (10).

3. Calibrate the bushing, using an adequate calibration tool (10).

4. Other operations of the mounting for both sides of the drum are identical; follow them in the order reverse to the order of dismounting. When mounting the bearing outer rings (14) into the covers (7), (8), and (10), observe the pairing with the bearing inner rings.

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5. Mount the retaining ring (17). When mounting the connecting shaft (7), it is necessary to observe the right position of the vibrators against each other— this is secured by the groove (A) on both ends of the shaft facing the pins (21).

SS13F204

5

SS13F205

6

SS13F229

7

6. Strike the pins (21) into both shafts (5), (6), and secure their position.

7. After mounting the covers (7) and (8), test the axial clearance of the bearings of both vibrators: 1.5 2.5 mm (0.06 - 0.10 in).

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Index Wheels - 44 Compaction drums - 160 Compaction front drum - Change fluid (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Compaction front drum - Component identification - Pad foot (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Compaction front drum - Component identification - Pad foot (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Compaction front drum - Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Compaction front drum - Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Compaction front drum - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Compaction front drum - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Compaction front drum - Install – Pad foot segments (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Compaction front drum - Install – Pad foot segments (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Compaction front drum - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Compaction front drum - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Compaction front drum - Remove – Pad foot segments (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Compaction front drum - Remove – Pad foot segments (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Compaction front drum shaft - Assemble – Vibrator (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Compaction front drum shaft - Assemble – Vibrator (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Compaction front drum shaft - Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Compaction front drum shaft - Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Compaction front drum shaft - Disassemble – Vibrator (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Compaction front drum shaft - Disassemble – Vibrator (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

(*) See content for specific models 47688018 12/06/2014

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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. © 2014 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.

47688018 12/06/2014 EN

SERVICE MANUAL Cab climate control SV208 SV210 SV212 SV216

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50

Contents Cab climate control - 50

[50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1

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Cab climate control - 50 Air conditioning - 200

SV208 SV210 SV212 SV216

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Contents Cab climate control - 50 Air conditioning - 200

FUNCTIONAL DATA Air conditioning Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Compressor drive belt Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

DIAGNOSTIC Air conditioning Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Cab climate control - Air conditioning

Air conditioning - Static description Heat is removed from the evaporator (5) inside the cab (low-pressure circuit) and delivered to the condenser (2), which is located in front of the engine radiator (high-pressure circuit). The compressor (1) sucks cooling vapors from the evaporator and directs them to the condenser (2). There, the cooling vapors are condensed and flow through the dehydrating filter (3) to the heat-expanding valve (4). The valve (4) sprays liquid refrigerant to the evaporator (5), where heat is absorbed from the cab. The liquid evaporates and the vapors are sucked into the compressor.

SS13F306

1

Component location Data: Cooling power Voltage Current Volume of air in evaporator Volume of air in condenser Refrigerant Refrigerant volume High-pressure protection Low-pressure protection

3.0 kW (4.1 Hp) 24 V 6A 400.0 m³ (14125.9 ft³)/h 900.0 m³ (31783.2 ft³)/h R 134a 0.9 kg (2.0 lb) 2.7 MPa (391.6 psi) 0.2 MPa (29.0 psi)

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Compressor drive belt - Replace 1. Loosen the bolts (1) and (2).

2. Loosen the belt (3) by swinging the compressor (4) to the left.

3. Remove the belt.

4. Insert a new belt.

5. The belt is tightened correctly when a force of 1.0 kg (2.2 lb) is applied perpendicular to the belt at the center of the span with a 3.0 mm (1/64 in) deflection.

SS13G151

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1

Cab climate control - Air conditioning

Air conditioning - Troubleshooting Problem The unit does not cool

Possible Cause Compressor belt Evaporator fan Fuses F7 Dehydrator filter

Electromagnetic latch

Correction Check the compressor belt.

Check the evaporator fan.

Check the fuses F7.

Check the refrigerant level in inspection hole of the dehydrator filter - leak (bubbles, fogging up, etc.).

Check the electromagnetic latch with the engine running and the A/C on - the latch doesn't react (no click in compressor).

• faulty fuse F7 • faulty thermostat • faulty pressure fuse

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Index Cab climate control - 50 Air conditioning - 200 Air conditioning - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Air conditioning - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Compressor drive belt - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. © 2014 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.

47688018 12/06/2014 EN

SERVICE MANUAL Electrical systems SV208 SV210 SV212 SV216

47688018 12/06/2014

55

Contents Electrical systems - 55

[55.011] Fuel tank system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.036] Hydraulic system control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7

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Electrical systems - 55 Fuel tank system - 011

SV208 SV210 SV212 SV216

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Contents Electrical systems - 55 Fuel tank system - 011

SERVICE Fuel level sensor Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Electrical systems - Fuel tank system

Fuel level sensor - Calibrate Prior operation: Remove the fuel level sensor. Please see Fuel level sensor - Remove (55.011).

1. Position the fuel gauge vertically; the fuel gauge float will fall down to the bottom of the fuel level sensor.

SS13A841

1

SS12C101

2

SS12N448

3

2. With the ignition key turned ON, the four-parameter screen will be displayed. Press MENU to enter the main menu on the instrument cluster.

3. Move the cursor (1) to SETUP 1 - UP DISPLAY, and confirm with Enter (2).

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Electrical systems - Fuel tank system

4. Move the cursor (1) to UTILITIES, and confirm with Enter (2).

SS13A049

4

SS13A050

5

SS13A051

6

SS13A052

7

5. Move the cursor (1) to ANALOG INPUT, confirm with Enter (2).

6. Move the cursor (1) to FUEL LEVEL, and confirm with Enter (2).

7. Move the cursor (1) to SET EMPTY POINT, and confirm with Enter (2).

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Electrical systems - Fuel tank system

8. Turn the fuel gauge 180 °. This action will move the fuel float to the top of the fuel level sensor which simulates a full tank. Leave it in this position.

SS13A842

8

SS13A893

9

9. Move the cursor (1) to SET FULL POINT, and confirm with Enter (2).

10. Move the cursor (1) to SET LOW FUEL LEVEL, and confirm with Enter (2).

SS13A053

10

SS13A054

11

11. Set the LOW FUEL value to 20 %, and confirm with Enter (2).

12. Press the MENU (3) push button step by step to move over to the four-parameter screen.

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Electrical systems - Fuel tank system

NOTICE: Turn OFF the master switch only after 30 s following Power View instrument setup to store the data in the computer memory. It is not allowed to change set parameters aside from those mentioned above when multifunctional display instrument or fuel gauge are replaced.

SS13A888

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12

Electrical systems - Fuel tank system

Fuel level sensor - Remove 1. Cut off the tape.

SS13F291

1

SS13F290

2

SS13F289

3

2. Disconnect the wiring.

3. Remove the fuel level sensor.

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Electrical systems - Fuel tank system

Fuel level sensor - Install 1. Connect the wiring to the new fuel gauge. Position the fuel gauge vertically; the fuel gauge float will fall down to the bottom of the fuel level sensor.

SS13A841

1

SS12C101

2

SS12N448

3

SS13A049

4

2. With the ignition key turned ON, the four-parameter screen will be displayed. Press MENU to enter the main menu on the instrument cluster.

3. Move the cursor (1) to SETUP 1 - UP DISPLAY, and confirm with Enter (2).

4. Move the cursor (1) to UTILITIES, and confirm with Enter (2).

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Electrical systems - Fuel tank system

5. Move the cursor (1) to ANALOG INPUT, confirm with Enter (2).

SS13A050

5

SS13A051

6

SS13A052

7

SS13A842

8

6. Move the cursor (1) to FUEL LEVEL, and confirm with Enter (2).

7. Move the cursor (1) to SET EMPTY POINT, and confirm with Enter (2).

8. Turn the fuel gauge 180 °. This action will move the fuel float to the top of the fuel level sensor which simulates a full tank. Leave it in this position.

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Electrical systems - Fuel tank system

9. Move the cursor (1) to SET FULL POINT, and confirm with Enter (2).

SS13A893

9

10. Move the cursor (1) to SET LOW FUEL LEVEL, and confirm with Enter (2).

SS13A053

10

SS13A054

11

SS13A888

12

11. Set the LOW FUEL value to 20 %, and confirm with Enter (2).

12. Press the MENU (3) push button step by step to move over to the four-parameter screen.

NOTICE: Turn OFF the master switch only after 30 s following Power View instrument setup to store the data in the computer memory. It is not allowed to change set parameters aside from those mentioned above when multifunctional display instrument or fuel gauge are replaced.

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Electrical systems - Fuel tank system

13. Install the fuel level sensor.

14. Tighten the bolts on the fuel level sensor.

SS13F289

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13

Index Electrical systems - 55 Fuel tank system - 011 Fuel level sensor - Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Fuel level sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Fuel level sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Electrical systems - 55 Hydraulic system control - 036

SV208 SV210 SV212 SV216

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Contents Electrical systems - 55 Hydraulic system control - 036

SERVICE Hydraulic fluid level sensor Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - Hydraulic system control

Hydraulic fluid level sensor - Remove 1. Remove the hydraulic tank cover.

SS13F005

1

SS13F133

2

SS13F134

3

SS13F132

4

2. Remove the level gauge cover.

3. Undo the bolts securing the level gauge.

4. Disconnect and remove the wiring.

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Electrical systems - Hydraulic system control

Hydraulic fluid level sensor - Install 1. Slowly place the level sensor in the hydraulic tank.

SS13F132

1

SS13F134

2

SS13F133

3

SS13F005

4

2. Install the bolts.

3. Install the level sensor cover.

4. Install the hydraulic tank cover.

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Index Electrical systems - 55 Hydraulic system control - 036 Hydraulic fluid level sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic fluid level sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Harnesses and connectors - 100

SV208 SV210 SV212 SV216

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Contents Electrical systems - 55 Harnesses and connectors - 100

FUNCTIONAL DATA Wire harnesses Component localisation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Component localisation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Electrical schema - A/C System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Electrical schema - One of two (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Electrical schema - Two of two (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Electrical schema - One of three (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Electrical schema - Two of three (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Electrical schema - Three of three (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Fuse and relay box Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

(*) See content for specific models 47688018 12/06/2014

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Electrical systems - Harnesses and connectors

Wire harnesses - Component localisation SV208 SV210

The battery connector is located on the left side under the cab.

Always disconnect the battery when working on the electrical wiring.

SS13G156

Position 1 2 3 4 5 6 7 8 9 10

Designation Hydraulic oil level sensor Safety beacon socket Clogged air filter switch Connector by wire of hood Engine temperature sensor Engine lubrication switch Alternator Starter Hydraulic oil temperature sensor Fuel level sensor

1

Position 11 12 13 14 15 16 17 18 19

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Designation Contactor Servo valve of the travel pump Electromagnetic valves of the vibration pump Fuse 50 A Longitudinal inclination sensor Brake pressure switch Cabin and hood lifting switch Battery disconnector Control unit

Electrical systems - Harnesses and connectors

SS13F333

Position Designation 1 Electromagnetic valve of brake 2 3 4

drum speed sensor Electromagnetic valve of fast travel speed Clogged filter pressure switch

5 6

Aggregate of cabin & hood lifting Electromagnetic valve of differential lock – left-hand wheel Steering pressure switch Electromagnetic valve of differential lock – right-hand wheel right wheel speed sensor

7 8 9

2

Position Designation 10 Electromagnetic valve of fast travel speed – right wheel 11 Electromagnetic valve of engine STOP 12 Left wheel speed sensor 13 Electromagnetic valve of fast travel speed – left wheel 14 Electromagnetic valve cabin lowering 15 Electromagnetic valve hood lowering 16 17

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Electromagnetic valve hood lifting Electromagnetic valve cab lifting

Electrical systems - Harnesses and connectors

Wire harnesses - Component localisation SV212 SV216

The battery connector is located on the left side under the cab.

Always disconnect the battery when working on the electrical wiring.

SS13F319

Position 1 2 3 4 5 6 7 8 9

Designation Hydraulic oil level sensor Safety beacon sprocket Restricted air filter switch Engine temperature sensor Engine lubrication switch Alternator Starter Hydraulic temperature sensor Fuel level sensor

1

Position 10 11 12 13 14 15 16 17 18 47688018 12/06/2014

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Designation Contactor Servo valve for the travel pump Electromagnetic valves on the vibration pump Fuse 50 A Longitudinal inclination sensor Brake pressure switch Cabin and hood lifting Battery disconnector RTM electronic

Electrical systems - Harnesses and connectors

SS13F320

Position 1 2 3 4 5 6 7 8 9 10 11

2

Designation Position Designation 12 Cab lifting solenoid Glowing 13 Motor connectors Solenoid valve for fast travel --- drum Drum speed sensor 14 left wheel speed sensor 15 Clogged hydraulic oil filter sensor Solenoid valve for fast travel --- left wheel 16 Brake pressure switch Solenoid valve for the RTM module 17 Differential. Lock solenoid valve — left-hand Aggregate of cabin and bonnet lifting wheel. Forward 18 Differential. Lock solenoid valve — Differential. Lock solenoid valve — right-hand right-hand wheel. Forward wheel. Backward Hydraulic oil thermometer sensor 19 Differential. Lock solenoid valve — left-hand wheel. Backward Brake magnet 20 Solenoid valve for bonnet lowering Right wheel speed sensor 21 Solenoid valve for cab lowering 22 Solenoid valve for fast travel — right wheel Solenoid valve for bonnet lifting

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schema - A/C System A/C system table Position 1 2 3 4 5

Designation Compressor Condenser fan A/C fan Fan control Battery

Position 6 7 8 9 10

SS13F308

1

A/C system

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Designation Relays Switch Thermostat Pressure fuse Compressor fuse

Electrical systems - Harnesses and connectors

SS13F323

2

Wiring diagram. Seat switch. Tier III (4x ATC)

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schema - One of two SV208 SV210

Schematic guide Line color Red Green Orange

Description Unswitched power Switched power Starting sequence

Wiring diagram - seat switch Tier III (4x ATC) Position A1 A2 A3 A4 B2 B3 E1 E2,3 E4,5 E6,7 E8,9 E10,11 E12,13 E14 E15 F1-12 G1,2 G3 H1 H2 H3 H4 H5 H6 H7 H8 H10 H11 H12 H17 K1 K2-9 K10 K11 M1 M2 M3 M4 M5 M6 M7

Designation Position Designation Front headlight switch Clicker for direction-indicator lights (optional) S4 Electronics to secure travel Rear headlight switch S5 Travel actuator S6 Warning light switch (optional) Multifunctional display Murphy PV-101 S7 Direction-indicator light switch (optional) Hydraulic oil thermometer sensor S8 Hazard beacon switch (optional) Horn pushbutton Float (displacer) in fuel tank S9 Hydraulics thermometer lighting Emergency brake pushbutton S11 Front fender lights (optional) S12 Backing horn switch (in travel actuator) Rear lamps (optional) S13 Neutral switch (in travel actuator) Front headlights S14 Float (displacer) inside hydraulic oil tank Rear headlights Fast travel switch S16 Left-hand direction-indicator lights (optional) S17 Selector switch for operating speed preset Right-hand direction-indicator lights Vibration selector switch S18 (optional) Cab lighting S19 Vibration switch (in travel actuator) Brake pressure switch Hazard beacon (optional) S21 Fuses S22 Seat switch Batteries S27 Vacuum switch for air filter clogged Alternator S28 Vacuum switch for hydraulic oil filter clogged Pilot lamp for direction-indicator lights S29 Cab fan selector switch (optional) Horn Front wiper switch S30 Rear wiper switch Backing horn (optional) S31 Washer push button Pilot lamp for hydraulic oil level S32 Pilot lamp for neutral S33 Heater fan selector switch Parking brake switch Pilot lamp for brake S35 Pilot lamp for vibration preset S36 Switch to reduce drum slip Engine idling switch Pilot lamp for differential interlock S37 Double pushbutton to adjust idle RPM Pilot lamp for battery recharging S39 V3 Pilot lamp for air filter clogged Interlocking LED (only with machines having cab-lifting alarm) V4-7 Interlocking LEDs Pilot lamp for hydraulic oil filter clogged X2-24 Pilot lamp for glowing (WTS) Interface connectors X27 Starting contactor Socket for hazard beacon Auxiliary relays X28-33 Interface connectors X34 Glowing contactor Socket for engine diagnostic Auxiliary relay X35-40 J1939 Connector Engine starter X41,42 Interface connectors Y1 Motor for cab lifting pump Solenoid valve for cab lifting Y2 Cab ventilation fan Solenoid valve for cab lowering Front wiper Y3 Solenoid valve for hood lifting Rear wiper Y4 Solenoid valve for hood lowering Windshield washer Y6 Solenoid valve for brake Rear-glass washer Y7 Solenoid valve for fast travel – left-hand wheel 47688018 12/06/2014

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Electrical systems - Harnesses and connectors

Position M8 P2 Q1 R1,2,5

Designation Heater fan Hydraulic oil thermometer Battery disconnector Resistors

S1 S2

Cab-lifting push button Hood-lifting push button

S3

Ignition box

Position Y8 Y9 Y10 Y11 Y13 Y14

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Designation Solenoid valve for fast travel – drum Solenoid valve vibrations 1 Solenoid valve for vibrations 2 Solenoid valve to disengage RTM differential interlock Servo valve for travel pump Solenoid valve for fast travel – right-hand wheel

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wiring diagram - seat switch Tier III (4x ATC)

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Electrical systems - Harnesses and connectors

RAIL14COM0403JA

1

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schema - Two of two SV208 SV210

Schematic guide Line color Red Green

Description Unswitched power Switched power

Wiring diagram - seat switch Tier III (4x ATC) Position A1 A2 A3 A4 B2 B3 E1 E2,3 E4,5 E6,7 E8,9 E10,11 E12,13 E14 E15 F1-12 G1,2 G3 H1 H2 H3 H4 H5 H6 H7 H8 H10 H11 H12 H17 K1 K2-9 K10 K11 M1 M2 M3 M4 M5 M6 M7

Designation Position Designation Front headlight switch Clicker for direction-indicator lights (optional) S4 Electronics to secure travel Rear headlight switch S5 Travel actuator S6 Warning light switch (optional) Multifunctional display Murphy PV-101 S7 Direction-indicator light switch (optional) Hydraulic oil thermometer sensor S8 Hazard beacon switch (optional) Horn pushbutton Float (displacer) in fuel tank S9 Hydraulics thermometer lighting Emergency brake pushbutton S11 Front fender lights (optional) S12 Backing horn switch (in travel actuator) Rear lamps (optional) S13 Neutral switch (in travel actuator) Front headlights S14 Float (displacer) inside hydraulic oil tank Rear headlights Fast travel switch S16 Left-hand direction – indicator lights S17 Selector switch for operating speed preset (optional) Right-hand direction – indicator lights Vibration selector switch S18 (optional) Cab lighting S19 Vibration switch (in travel actuator) Brake pressure switch Hazard beacon (optional) S21 Fuses S22 Seat switch Batteries S27 Vacuum switch for air filter clogged Alternator S28 Vacuum switch for hydraulic oil filter clogged Pilot lamp for direction-indicator lights S29 Cab fan selector switch (optional) Horn Front wiper switch S30 Rear wiper switch Backing horn (optional) S31 Washer push button Pilot lamp for hydraulic oil level S32 Pilot lamp for neutral S33 Heater fan selector switch Parking brake switch Pilot lamp for brake S35 Pilot lamp for vibration preset S36 Switch to reduce drum slip Engine idling switch Pilot lamp for differential interlock S37 Double pushbutton to adjust idle RPM Pilot lamp for battery recharging S39 V3 Pilot lamp for air filter clogged Interlocking LED (only with machines having cab-lifting alarm) V4-7 Interlocking LEDs Pilot lamp for hydraulic oil filter clogged X2-24 Pilot lamp for glowing (WTS) Interface connectors X27 Starting contactor Socket for hazard beacon Auxiliary relays X28-33 Interface connectors X34 Glowing contactor Socket for engine diagnostic Auxiliary relay X35-40 J1939 Connector Engine starter X41,42 Interface connectors Y1 Motor for cab lifting pump Solenoid valve for cab lifting Y2 Cab ventilation fan Solenoid valve for cab lowering Front wiper Y3 Solenoid valve for hood lifting Rear wiper Y4 Solenoid valve for hood lowering Windshield washer Y6 Solenoid valve for brake Rear glass washer Y7 Solenoid valve for fast travel – left-hand wheel 47688018 12/06/2014

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Electrical systems - Harnesses and connectors

Position M8 P2 Q1 R1,2,5

Designation Heater fan Hydraulic oil thermometer Battery disconnector Resistors

S1 S2

Cab-lifting push button Hood-lifting push button

S3

Ignition box

Position Y8 Y9 Y10 Y11 Y13 Y14

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Designation Solenoid valve for fast travel – drum Solenoid valve vibrations 1 Solenoid valve for vibrations 2 Solenoid valve to disengage RTM differential interlock Servo valve for travel pump Solenoid valve for fast travel – right-hand wheel

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wiring diagram - seat switch Tier III (4x ATC)

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Electrical systems - Harnesses and connectors

RAIL14COM0404JA

1

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schema - One of three SV212 SV216

Schematic guide Line color Red Green Orange

Description Unswitched power Switched power Starting sequence

Wiring diagram - seat switch Tier III Position A1 A2 A3 A4 B2 B3 E1 E2,3 E4,5 E6,7 E8,9 E10,11 E12,13 E14 E15 F1-12 G1,2 G3 H1 H2 H3 H4 H5 H6 H7 H8 H10 H11 H12 H17 K1 K2-9 K10 K11 M1 M2 M3 M4 M5 M6 M7

Designation Position Designation Ignition box Clicker for direction-indicator lights (optional) S3 Electronics to secure travel Front headlight switch S4 Travel actuator Rear headlight switch S5 Multifunctional display Murphy PV-101 S6 Warning light switch (optional) Hydraulic oil thermometer sensor S7 Direction-indicator light switch (optional) Float (displacer) in fuel tank S8 Hazard beacon switch (optional) Hydraulics thermometer lighting Horn pushbutton S9 Emergency brake pushbutton Front fender lights (optional) S11 Rear lamps (optional) S12 Backing horn switch (in travel actuator) Front headlights S13 Neutral switch (in travel actuator) Rear headlights S14 Float (displacer) inside hydraulic oil tank Fast travel switch Left-hand direction – indicator lights (optional) S16 Right-hand direction – indicator lights S17 Selector switch for operating speed preset (optional) Vibration selector switch Cab lighting S18 Hazard beacon (optional) S19 Vibration switch (in travel actuator) Fuses Brake pressure switch S21 Batteries S22 Seat switch Alternator S27 Vacuum switch for air filter clogged Pilot lamp for direction-indicator lights S28 Vacuum switch for hydraulic oil filter clogged (optional) Horn S29 Cab fan selector switch Front wiper switch Backing horn (optional) S30 Rear wiper switch Pilot lamp for hydraulic oil level S31 Washer push button Pilot lamp for neutral S32 Pilot lamp for brake S33 Heater fan selector switch Parking brake switch Pilot lamp for vibration preset S35 Pilot lamp for differential interlock S36 Switch to reduce drum slip Engine idling switch Pilot lamp for battery recharging S37 Double pushbutton to adjust idle RPM Pilot lamp for air filter clogged S39 V3 Pilot lamp for hydraulic oil filter clogged Interlocking LED (only with machines having cab-lifting alarm) V4-7 Interlocking LEDs Pilot lamp for glowing (WTS) X2-24 Starting contactor Interface connectors Auxiliary relays X27 Socket for hazard beacon X28-33 Interface connectors Glowing contactor Auxiliary relay X34 Socket for engine diagnostic Engine starter X35-40 J1939 Connector X41,42 Interface connectors Motor for cab lifting pump Y1 Cab ventilation fan Solenoid valve for cab lifting Front wiper Y2 Solenoid valve for cab lowering Rear wiper Y3 Solenoid valve for bonnet lifting Windscreen washer Y4 Solenoid valve for bonnet lowering Rear-glass washer Y6 Solenoid valve for brake 47688018 12/06/2014

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Electrical systems - Harnesses and connectors

Position M8 P2 Q1 R1,2,5,6 R3

Designation

Position Y7 Y8 Y9 Y10 Y11

Heater fan Hydraulic oil thermometer Battery disconnector Resistors Engine preheating

R4 S1

Engine revolution control potentiometer Cab-lifting push button

S2

Bonnet lifting pushbutton

Y13 Y14

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Designation Solenoid valve for fast travel – left-hand wheel Solenoid valve for fast travel – drum Solenoid valve vibrations 1 Solenoid valve for vibrations 2 Solenoid valve to disengage RTM differential interlock Servo valve for travel pump Solenoid valve for fast travel – right-hand wheel

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wiring diagram - seat switch Tier III

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Electrical systems - Harnesses and connectors

RAIL14COM0401JA

1

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schema - Two of three SV212 SV216

Schematic guide Line color Red Green

Description Unswitched power Switched power

Wiring diagram. Seat switch. Tier III Position A1 A2 A3 A4 B2 B3 E1 E2,3 E4,5 E6,7 E8,9 E10,11 E12,13 E14 E15 F1-12 G1,2 G3 H1 H2 H3 H4 H5 H6 H7 H8 H10 H11 H12 H17 K1 K2-9 K10 K11 M1 M2 M3 M4 M5 M6 M7 M8

Designation Position Designation Ignition box Clicker for direction-indicator lights (optional) S3 Electronics to secure travel Front headlight switch S4 Travel actuator Rear headlight switch S5 Multifunctional display Murphy PV-101 S6 Warning light switch (optional) Hydraulic oil thermometer sensor S7 Direction-indicator light switch (optional) Float (displacer) in fuel tank S8 Hazard beacon switch (optional) Hydraulics thermometer lighting Horn pushbutton S9 Emergency brake pushbutton Front fender lights (optional) S11 Rear lamps (optional) S12 Backing horn switch (in travel actuator) Front headlights S13 Neutral switch (in travel actuator) Rear headlights S14 Float (displacer) inside hydraulic oil tank Fast travel switch Left-hand direction – indicator lights (optional) S16 Right-hand direction – indicator lights S17 Selector switch for operating speed preset (optional) Vibration selector switch Cab lighting S18 Hazard beacon (optional) S19 Vibration switch (in travel actuator) Fuses Brake pressure switch S21 Batteries S22 Seat switch Alternator S27 Vacuum switch for air filter clogged Pilot lamp for direction-indicator lights S28 Vacuum switch for hydraulic oil filter clogged (optional) Horn S29 Cab fan selector switch Front wiper switch Backing horn (optional) S30 Rear wiper switch Pilot lamp for hydraulic oil level S31 Washer push button Pilot lamp for neutral S32 Pilot lamp for brake S33 Heater fan selector switch Parking brake switch Pilot lamp for vibration preset S35 Pilot lamp for differential interlock S36 Switch to reduce drum slip Engine idling switch Pilot lamp for battery recharging S37 Double pushbutton to adjust idle RPM Pilot lamp for air filter clogged S39 V3 Pilot lamp for hydraulic oil filter clogged Interlocking LED (only with machines having cab-lifting alarm) V4-7 Interlocking LEDs Pilot lamp for glowing (WTS) X2-24 Starting contactor Interface connectors Auxiliary relays X27 Socket for hazard beacon X28-33 Interface connectors Glowing contactor Auxiliary relay X34 Socket for engine diagnostic Engine starter X35-40 J1939 Connector X41,42 Interface connectors Motor for cab lifting pump Y1 Cab ventilation fan Solenoid valve for cab lifting Front wiper Y2 Solenoid valve for cab lowering Rear wiper Y3 Solenoid valve for bonnet lifting Windscreen washer Y4 Solenoid valve for bonnet lowering Rear-glass washer Y6 Solenoid valve for brake Y7 Heater fan Solenoid valve for fast travel – left-hand wheel 47688018 12/06/2014

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Electrical systems - Harnesses and connectors

Position P2 Q1 R1,2,5,6 R3

Designation Hydraulic oil thermometer Battery disconnector Resistors Engine preheating

Position Y8 Y9 Y10 Y11

R4 S1

Engine revolution control potentiometer Cab-lifting push button

S2

Bonnet lifting pushbutton

Y13 Y14

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Designation Solenoid valve for fast travel – drum Solenoid valve vibrations 1 Solenoid valve for vibrations 2 Solenoid valve to disengage RTM differential interlock Servo valve for travel pump Solenoid valve for fast travel – right-hand wheel

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wiring diagram. Seat switch. Tier III

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RAIL14COM0402JA

1

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Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schema - Three of three SV212 SV216

Wiring diagram - seat switch Tier III Position A1 A2 A3 A4 B2 B3 E1 E2,3 E4,5 E6,7 E8,9 E10,11 E12,13

Designation Position Designation Ignition box Clicker for direction-indicator lights (optional) S3 Electronics to secure travel Front headlight switch S4 Travel actuator Rear headlight switch S5 Multifunctional display Murphy PV-101 S6 Warning light switch (optional) Hydraulic oil thermometer sensor S7 Direction-indicator light switch (optional) Float (displacer) in fuel tank S8 Hazard beacon switch (optional) Hydraulics thermometer lighting Horn pushbutton S9 Emergency brake pushbutton Front fender lights (optional) S11 Rear lamps (optional) S12 Backing horn switch (in travel actuator) Front headlights S13 Neutral switch (in travel actuator) Rear headlights S14 Float (displacer) inside hydraulic oil tank Fast travel switch Left-hand direction – indicator lights (optional) S16 Right-hand direction – indicator lights S17 Selector switch for operating speed preset (optional) E14 Vibration selector switch Cab lighting S18 E15 Hazard beacon (optional) S19 Vibration switch (in travel actuator) F1-12 Fuses Brake pressure switch S21 Batteries G1,2 S22 Seat switch Alternator G3 S27 Vacuum switch for air filter clogged H1 Pilot lamp for direction-indicator lights S28 Vacuum switch for hydraulic oil filter clogged (optional) H2 Horn S29 Cab fan selector switch H3 Front wiper switch Backing horn (optional) S30 H4 Rear wiper switch Pilot lamp for hydraulic oil level S31 H5 Washer push button Pilot lamp for neutral S32 H6 Pilot lamp for brake S33 Heater fan selector switch H7 Parking brake switch Pilot lamp for vibration preset S35 H8 Pilot lamp for differential interlock S36 Switch to reduce drum slip H10 Engine idling switch Pilot lamp for battery recharging S37 H11 Double pushbutton to adjust idle RPM Pilot lamp for air filter clogged S39 H12 V3 Pilot lamp for hydraulic oil filter clogged Interlocking LED (only with machines having cab-lifting alarm) H17 V4-7 Interlocking LEDs Pilot lamp for glowing (WTS) K1 X2-24 Starting contactor Interface connectors K2-9 Auxiliary relays X27 Socket for hazard beacon K10 X28-33 Interface connectors Glowing contactor K11 Auxiliary relay X34 Socket for engine diagnostic M1 Engine starter X35-40 J1939 Connector M2 X41,42 Interface connectors Motor for cab lifting pump M3 Y1 Cab ventilation fan Solenoid valve for cab lifting M4 Front wiper Y2 Solenoid valve for cab lowering M5 Rear wiper Y3 Solenoid valve for bonnet lifting M6 Windscreen washer Y4 Solenoid valve for bonnet lowering M7 Rear-glass washer Y6\ Solenoid valve for brake M8 Y7 Heater fan Solenoid valve for fast travel – left-hand wheel P2 Hydraulic oil thermometer Y8 Solenoid valve for fast travel – drum Battery disconnector Y9 Q1 Solenoid valve vibrations 1 R1,2,5,6 Resistors Y10 Solenoid valve for vibrations 2 R3 Engine preheating Y11 Solenoid valve to disengage RTM differential interlock 47688018 12/06/2014

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Electrical systems - Harnesses and connectors

Position Designation R4 Engine revolution control potentiometer S1 Cab-lifting push button S2

Position Designation Y13 Servo valve for travel pump Y14 Solenoid valve for fast travel – right-hand wheel

Bonnet lifting pushbutton

SS13F326

1

Wiring diagram - seat switch Tier III

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Fuse and relay box - Component localisation Fuse block ATTENTION: Replace fuses only with fuses of identical value.

Fuse F1 - 20 A

Fuse F2 - 10 A Fuse F3 - 7.5 A

Fuse F4 - 1 A Fuse F5 - 5 A

Fuse F6 - 15 A

Fuse F7 - 20 A Fuse F8

(upper fuse) front + rear lamps, front fender lights + rear lights, auxiliary headlamps, dashboard instrument illumination, hood lifting - lowering and driver’s control stand cab light, loud horn, direction indicator lights, beacon brake, engine STOP, travel, vibration, brake lights, return horn, hydraulic oil level indicator lamp, vibration contact indicator lamp, brake indicator lamp, indicator lamp for zero position of travel actuator POWER VIEW, J1939 socket power supply hydraulic-oil thermometer, indicator lamp for vacuum in engine suction filter, regarding indicator lamp: indicator lamp for hydraulic oil filter fouled, glowing indicator lamp, engine RPM switches ventilation and heater fan, front wiper and rear wiper, front washer and rear washer reserve (air conditioner / ROPS2D) reserve

SS13F309

1

SS13F310

2

Fuse F9 (Option) Serves to protect the electric pump used for lifting and lowering the hood and the operator's station.

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Electrical systems - Harnesses and connectors

Engine fuses Position Fuse (F10) Fuse (F11) Fuse (F12)

Designation engine preheating - 125 A engine preheating - 30 A car radio

SS13F311

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3

Index Electrical systems - 55 Harnesses and connectors - 100 Fuse and relay box - Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Wire harnesses - Component localisation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Wire harnesses - Component localisation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Wire harnesses - Electrical schema - A/C System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Wire harnesses - Electrical schema - One of three (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Wire harnesses - Electrical schema - One of two (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Wire harnesses - Electrical schema - Three of three (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Wire harnesses - Electrical schema - Two of three (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Wire harnesses - Electrical schema - Two of two (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

(*) See content for specific models 47688018 12/06/2014

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Electrical systems - 55 Battery - 302

SV208 SV210 SV212 SV216

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Contents Electrical systems - 55 Battery - 302

FUNCTIONAL DATA Battery connect and disconnect system Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - Battery

Battery connect and disconnect system - Component localisation The battery connector is located on the left side under the cabin.

NOTICE: When driving is ended, please use the master switch to disconnect the battery!

After you have removed the ignition key from the switch box, wait 30 s before you cut OFF the master switch. This time limit must be observed for the ECM engine data to be stored.

While working on the electrical wiring, always disconnect the battery.

When washing the machine ALWAYS cut OFF the master switch.

SS13F173

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1

Electrical systems - Battery

Battery - Charging NOTE: The batteries are factory-filled with acid with a density of 4.8 L/min (1.3 US gpm) and sufficiently charged for immediate use. In case of insufficient starting power, recharging is necessary.

1. The battery must be recharged if the static voltage drops below 12.5 V as a result of a long storage period. The static voltage should be checked upon the expiry of 1.9 - 3.8 L (2.0 - 4.0 US qt) after the date of production. If the static voltage is lower than 12.5 V, the battery must be recharged before further storage to the level from 12.7 - 12.8 V. The measurement of static voltage is performed by means of a digital multimeter. The measurement must be performed under a temperature of approximately 20 °C (68 °F).

2. Ensure the adequate ventilation of the working areas.

3. Use only suitable direct-current chargers.

4. Connect the plus pole of the battery with the plus output of the charger; similarly, connect the minus pole.

5. Turn on the charge only after connecting the battery and turn it off only after the battery has been recharged.

6. Recommended charging current: 1/10 of the battery capacity in amperes (A).

7. If the acid temperature exceeds 55 °C (131 °F), interrupt charging.

8. The battery is fully charged if the charging voltage does not increase in the course of two hours.

9. After charging has been completed, always measure the static voltage (no sooner than 1 h after the end of charging).

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Index Electrical systems - 55 Battery - 302 Battery - Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Battery connect and disconnect system - Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Cab controls - 512

SV208 SV210 SV212 SV216

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Contents Electrical systems - 55 Cab controls - 512

SERVICE Instrument cluster Configure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - Cab controls

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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Electrical systems - Cab controls

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: 1.

Engine operating hours

2.

Engine speed

3.

Electrical system voltage

4.

Engine load in % at actual engine speed

5.

Coolant temperature

6.

Engine oil pressure

7.

Fuel level

8.

Instantaneous consumption

9.

Accelerator pedal position

SS12C302

7

SS12C303

8

SS12C305

9

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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Electrical systems - Cab controls

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.

1.

Engine speed (RPM)

2.

Coolant temperature

3.

Engine oil pressure

4.

Engine load in percentage at actual engine speed

5.

Electrical system voltage

6.

Engine operating hours

7.

Fuel level

8.

Current fuel consumption rate

9.

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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Electrical systems - Cab controls

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

SV208 SV210 SV212 SV216

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

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

DIAGNOSTIC Instrument cluster Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Electrical systems - Warning indicators, alarms, and instruments

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

Fault code list Fault code 115

Lamp color Red

122

Amber

123

Amber

125

Amber

131

Red

132

Red

133

Red

134

Red

135

Amber

141

Amber

143

Amber

144

Amber

145

Amber

146

Amber

147

Red

148

Red

151

Red

153

Amber

154

Amber

155

Red

187

Amber

193

Amber

194

Amber

195

Amber

Description Definition System diagnostic code # 2 Engine speed/position sensor circuit lost both of two signals from the magnetic pickup sensor - data erratic, intermittent, or incorrect Boost pressure Intake manifold pressure sensor circuit - voltage above normal, or shorted to high source Boost pressure Intake manifold pressure sensor circuit - voltage below normal, or shorted to low source Engine intake manifold #1 Intake manifold 1 pressure - data valid but below pressure normal operating range - moderately severe level Accelerator pedal position Accelerator pedal or lever position sensor circuit voltage above normal, or shorted to high source Accelerator pedal position Accelerator pedal or lever position sensor circuit voltage below normal, or shorted to low source Remote accelerator Remote accelerator pedal or lever position sensor circuit - voltage above normal, or shorted to high source Remote accelerator Remote accelerator pedal or lever position sensor circuit - voltage below normal, or shorted to low source Engine oil pressure Oil pressure sensor circuit - voltage above normal, or shorted to high source Engine oil pressure Oil pressure sensor circuit - voltage below normal, or shorted to low source Engine oil pressure Oil pressure low - data valid but below normal operational range - moderately severe level Engine coolant temperature Coolant temperature sensor circuit - voltage above normal, or shorted to high source Engine coolant temperature Coolant temperature sensor circuit - voltage below normal, or shorted to low source Engine coolant temperature Coolant temperature high - data valid but above normal operational range - moderately severe level Accelerator pedal position Accelerator pedal or lever position sensor circuit abnormal frequency, pulse width, or period Accelerator pedal position accelerator pedal or lever position sensor circuit abnormal frequency, pulse width, or period Engine coolant temperature Coolant temperature low - data valid but above normal operational range - most severe level Intake manifold #1 Intake manifold air temperature sensor circuit temperature Voltage Above Normal, or Shorted to High Source Intake manifold #1 Intake manifold air temperature sensor circuit temperature voltage below normal, or shorted to low source Intake manifold #1 Intake manifold air temperature high – data valid temperature but above normal operational range - most severe 5 volts DC supply Sensor supply voltage #2 circuit - voltage below normal, or shorted to low source Cruise control Cruise control (resistive) signal circuit - voltage above normal, or shorted to high source Cruise control Cruise control (resistive) signal circuit - voltage below normal, or shorted to low source Coolant level Coolant level sensor circuit - voltage above normal, or shorted to high source 47688018 12/06/2014

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Electrical systems - Warning indicators, alarms, and instruments

196

Amber

Coolant level

197

Amber

Coolant level

221

Amber

Barometric pressure

222

Amber

Barometric pressure

227

Amber

5 volts DC supply

234

Red

Engine speed

235

Red

Coolant level

237

Amber

External speed input

238

Amber

System diagnostic code # 1

239

Amber

System diagnostic code #2

241

Amber

Wheel-based vehicle speed

242

Amber

Wheel-based vehicle speed

244

Amber

Red stop lamp

245

Amber

271

Amber

272

Amber

281

Amber

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

285

Amber

SAE J1939 datalink

286

Amber

SAE J1939 datalink

287

Red

Accelerator pedal position

288

Red

Remote accelerator

292

Red

Auxiliary temperature 1

293

Amber

OEM temperature

294

Amber

OEM temperature

295

Amber

Barometric pressure

296

Red

Auxiliary pressure

297

Amber

Auxiliary pressure

298

Amber

Auxiliary pressure

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

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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 - 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 - Fault code index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Instrument cluster - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Electrical systems - 55 FAULT CODES - DTC

SV208 SV210 SV212 SV216

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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. © 2014 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.

47688018 12/06/2014 EN

47688018 12/06/2014 EN

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

PRINTED IN U.S.A. © 2014 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.

47688018 12/06/2014 EN