Case SV208D Tier 4B (final) Vibratory Roller Service Manual PN 48150518 – PDF DOWNLOAD

SV208D Tier 4B (final) Vibratory Roller PIN DDDS208DNHWTA2003 and above

SERVICE MANUAL Printed in U.S.A. © 2018 CNH Industrial America LLC. All Rights Reserved.

Part number 48150518

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

1st edition English February 2018

SERVICE MANUAL SV208D

48150518 26/02/2018 EN

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

Engine....................................................................................... 10 [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.310] Aftercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

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

Hydraulic systems....................................................................... 35 [35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.106] Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.995] Compaction/vibration hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4

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

Steering..................................................................................... 41 [41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1 [41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 [41.206] Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3 [41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.4

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

Electrical systems ....................................................................... 55 48150518 26/02/2018

[55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6

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

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INTRODUCTION

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Contents INTRODUCTION Foreword - Important notice regarding equipment servicing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety rules - Ecology and the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Safety rules - Recovery and towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Safety rules - Welding on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Safety rules - Fuel system maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Safety rules - Cooling system maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Safety rules - Hydraulic system maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Safety rules - Tools and equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Torque - Minimum tightening torques for normal assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Torque - Standard torque data for hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Basic instructions - Shop and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Maintenance chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Basic instructions - Towing a disabled machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Basic instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Hydraulic contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 General specification SV208D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Part identification - Engine serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Product identification - Machine orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Part identification - Machine components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

(*) See content for specific models 48150518 26/02/2018

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INTRODUCTION

Foreword - Important notice regarding equipment servicing SV208D

NA

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

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

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

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

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

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

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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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INTRODUCTION

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

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

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

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

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

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

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

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

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

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

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

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

Wear protective equipment when appropriate.

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

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

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

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

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

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

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

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

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

Always keep windows, mirrors, all lighting, and Slow-Moving Vehicle (SMV) emblem clean to provide the best possible visibility while you operate the machine.

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

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

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

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

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

5. Turn off the engine and remove the key.

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

2. Disengage all drive systems.

3.

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

Make sure all drive systems are fully disengaged.

Failure to comply could result in death or serious injury.

W0113A

Shift the transmission into neutral.

4. Apply the parking brake.

General safety rules specific to this machine Always have the machine moving when in vibration mode. The vibrator bearing only receives lubrication when the machine is moving.

Do not change the vibration amplitude when driving. It is always necessary to stop first and then select a different amplitude.

Do not adjust the heating valve control rod while driving.

Do not roll and compact per bearing capacity of subsoil at such a distance from the edge of slopes or trenches, where hazard of a landslide or a shoulder breaking off (dropping) together with the machine could occur.

Do not roll and compact with vibration at such a distance from walls, cuts, slopes, where their slip (slide) would happen because the operator and the machine could get covered with debris.

Do not compact with vibration at such a distance from buildings or facilities and equipment within which the risk of them being damaged due to vibration transfer impact.

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

Service the machine on a firm, level surface.

Install guards and shields after you service the machine.

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

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

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

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

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

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INTRODUCTION

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

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

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

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

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

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

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

Always wash your hands after you handle battery components.

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INTRODUCTION

Wheels and tires Make sure that tires are correctly inflated. Do not exceed any recommended load or pressure. Follow the instructions in the manual for proper tire inflation.

Tires are heavy. Handling tires without proper equipment could cause death or serious injury.

Never weld on a wheel with a tire installed. Always remove the tire completely from the wheel prior to welding.

Always have a qualified tire technician service the tires and wheels. If a tire has lost all pressure, take the tire and wheel to a tire shop or your dealer for service. Explosive separation of the tire can cause serious injury.

DO NOT weld to a wheel or rim until the tire is completely removed. Inflated tires can generate a gas mixture with the air that can be ignited by high temperatures from welding procedures performed on the wheel or rim. Removing the air or loosening the tire on the rim (breaking the bead) will NOT eliminate the hazard. This condition can exist whether tires are inflated or deflated. The tire MUST be completely removed from the wheel or rim prior to welding the wheel or rim.

Driving on public roads and general transportation safety NOTICE: The standard type of the machine is not intended for driving on public road. When on the road, the machine should be transported on a vehicle. In the unavoidable situation to drive the machine on public roads for shorter distances, follow the below safety precautions.

Comply with local laws and regulations.

Use appropriate lighting to meet local regulations.

Make sure that the SMV emblem is visible.

Use safety chains for trailed equipment when safety chains are provided with machine or equipment.

Lift implements and attachments high enough above ground to prevent accidental contact with road.

When you transport equipment or a machine on a transport trailer, make sure that it is properly secured. Be sure the SMV on the equipment or machine is covered while being transported on a trailer.

Be aware of overhead structures or power lines and make sure that the machine and/or attachments can pass safely under.

Travel speed should be such that you maintain complete control and machine stability at all times.

Slow down and signal before turning.

Pull over to allow faster traffic to pass.

Follow correct towing procedure for equipment with or without brakes.

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

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

Always have a fire extinguisher on or near the machine.

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

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

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

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

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

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

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

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

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INTRODUCTION

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

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

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

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

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

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

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

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

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

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

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

Keep out of reach of children and other unauthorized persons.

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

Never disconnect or bypass the operator presence system.

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

Reflectors and warning lights You must use flashing amber warning lights when you operate equipment on public roads.

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INTRODUCTION

Seat belts Seat belts must be worn at all times.

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

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

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

• Replace all parts that have damage or wear.

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

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

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

• Keep seat belts clean and dry.

• Clean belts only with soap solution and warm water.

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

To fasten the belt: 1. Sit in the operator’s.

2. Adjust the seat so all controls are easily accessible and operator comfort is achieved.

3. Pull the seat belt cross your lap and insert the metal end into the latch mechanism until a click is heard.

4. Make sure that belt lays flat across the operator lap and it is secure in the latch mechanism.

To release the belt: Press the red release button on the buckle and guide the retractable belt back into the reel.

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SS12C077

1

INTRODUCTION

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

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

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

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

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

Roll Over Protective Structure (ROPS) The Roll Over Protective Structure (ROPS) Product Identification Number (PIN) plate is on right-hand rear post.

The plate provides information such as the ROPS PIN, the gross weight, approval, regulation, and model number of the machine.

RAIL14COM0260AA

2

Air-conditioning system The air-conditioning system is under high pressure. Do not disconnect any lines. The release of high pressure can cause serious injury.

The air-conditioning system contains gases that are harmful to the environment when released into the atmosphere.

Do not attempt to service or repair the system.

Only trained service technicians can service, repair, or recharge the air-conditioning system.

Backup alarm system Place the travel controller in the reverse travel position and an audible alarm will sound repeatedly until the operator moves the travel controller into neutral position or forward travel position.

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INTRODUCTION

The audible backup alarm system notifies others in the area that the machine will be or is moving in reverse.

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

DCAPLT5NE020S2A

3

87358697

4

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

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

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

MSDS are available from your dealer.

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

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

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

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

Keep out of reach or children or other unauthorized persons.

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INTRODUCTION

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

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

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

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

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

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

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

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

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

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

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

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

Do not jump off of the machine.

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

Face the machine when you mount and dismount the machine.

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

Never mount or dismount from a moving machine.

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

Working at heights When the normal use and maintenance of the machine requires you to work at heights: • Correctly use installed steps, ladders, and railings.

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

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

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

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INTRODUCTION

Lifting and overhead loads Never use loader buckets, forks, etc. or other lifting, handling, or digging equipment to lift persons.

Do not use raised equipment as a work platform.

Know the full area of movement of the machine and equipment and do not enter or permit anyone to enter the area of movement while the machine is in operation.

Never enter or permit anyone to enter the area underneath raised equipment. Equipment and/or loads can fall unexpectedly and crush persons underneath it.

Do not leave equipment in raised position while parked or during service, unless securely supported. Hydraulic cylinders must be mechanically locked or supported if they are left in a raised position for service or access.

Equipment and associated loads can block visibility and cause an accident. Do not operate with insufficient visibility.

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INTRODUCTION

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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INTRODUCTION

Safety rules - Recovery and towing Incorrect towing procedures can cause accidents. When towing a disabled machine, follow the procedure in this manual.

The operator on a towed machine must steer the machine in the direction of towing.

No person may stay on the machine, while it is being towed.

When towing, make sure persons present stay within sufficient distance to avoid injury if the tow cable breaks or the hitch is damaged.

To tow, use unbroken tow ropes or tow bar of sufficient loading capacity – 1.5 times higher than the weight of towed machine. Use of chains to tow the machine is prohibited. Never use a tow cable when towing the roller - downhill in particular. Use the tow bar!

The maximum. permissible deflection is 30° away from the forward direction of towing.

The towing machine must have sufficient tractive force (power), weight and brake power.

When towing downhill, use a rope to attach another towing machine to the rear part of the towed machine to prevent its uncontrolled motion.

If the engine of the towed roller is not working, the steering will not work and the service brake is not fully operable (unable to generate air pressure). Follow the towing procedure in Basic instructions - Towing a disabled machine () of this manual to release the parking brake but be aware the machine will not be braked.

Unless the engine works, secure the roller immediately after towing against any motion. Follow the procedure in Basic instructions - Towing a disabled machine () of this manual to return the parking brake to normal operation.

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INTRODUCTION

Safety rules - Welding on the machine DANGER Improper operation or service of this machine can result in an accident.

Any unauthorized modifications made to this machine can have serious consequences. Consult an authorized dealer on changes, additions, or modifications that may be required for this machine. Do not make any unauthorized modifications.

Failure to comply will result in death or serious injury.

D0030A

CAUTION Fire hazard!

Remove all flammable and explosive materials from the area around the welding location. Shield flammable material that you cannot remove from the immediate area. Always have a fireguard and fire extinguisher available nearby.

Failure to comply could result in minor or moderate injury.

C0062A

Whenever carrying out a welding operation on the machine as authorized by the manufacturer and in accordance with manufacturer’s instructions you must: • Disconnect the batteries.

• Disconnect the Engine Control Unit (ECU).

• Disconnect the alternator B+ and D+ terminal wires.

• Connect the welding apparatus ground cable to the component on which the welding operation is to be performed.

Never connect the welding apparatus ground to a component of the hydraulic system.

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INTRODUCTION

Safety rules - Fuel system maintenance Fuel vapors are explosive and flammable. Do not smoke while handling fuel. Keep fuel away from flames or sparks.

Turn off the engine and remove the key before servicing. Always work in a well-ventilated area. Clean up spilled fuel immediately.

Improper use of solvents can result in fire or explosion. Do not use gasoline or low flash point solvents to clean the fuel filter and/or the fuel pump. Clean only in a well-ventilated area away from sources of sparks or flame, including any appliances with a pilot light.

Drain the fuel-water separator into a suitable container and dispose of the contents in accordance with local environmental regulations.

Diesel fuel escaping under pressure can penetrate the skin, causing serious injury. Do not use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear protective gloves and eye protection. If any fluid makes contact with the skin, seek medical attention immediately to ensure gangrene does not form.

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INTRODUCTION

Safety rules - Cooling system maintenance Do not remove the filler plug until engine coolant temperature drops below 50 °C (122.0 °F). If the filler plug is removed at a higher temperature, there is risk of vapor or coolant scalding due to the inner overpressure effect.

When handling lubricants (oil, grease, etc.) and other chemical products, always follow instructions for their proper use.

Use proper containers to collect fluid. Dispose of fluids and filters in a way that protects the environment and complies with applicable laws.

Do not smoke or use an open flame during the servicing procedure. Use eye protection.

Do not handle engine coolant, engine oil or hydraulic oil at temperatures that exceed 49 °C (120.2 °F).

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INTRODUCTION

Safety rules - Hydraulic system maintenance Hydraulic oil escaping under pressure can penetrate the skin, causing serious injury or infection. To prevent personal injury: Relieve all pressure before disconnecting fluid lines. Before pressurizing, make sure all connections are tight and components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately.

When handling lubricants (oil, grease etc.) and other chemical products, always follow instructions for their proper use.

Use proper containers to collect fluid. Dispose of fluids and filters in a way that protects the environment and complies with applicable law.

Do not smoke or use an open flame during the servicing procedure. Use eye protection. Do not handle engine coolant, engine oil or hydraulic oil at temperatures that exceed 49 °C (120.2 °F).

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INTRODUCTION

Safety rules - Tools and equipment Tools, lifting equipment, slings, chocks, and other equipment must be in safe operating and working condition.

Metal splinters can cause injury when accessory bolts are being driven in and out. Therefore, a brass or copper mandrel should be used and protective goggles must be worn.

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INTRODUCTION

Torque - Minimum tightening torques for normal assembly METRIC NON-FLANGED HARDWARE NOM. SIZE

M4 M5 M6 M8

CLASS 8.8 BOLT and CLASS 8 NUT PLATED UNPLATED W/ZnCr

CLASS 10.9 BOLT and CLASS 10 NUT PLATED UNPLATED W/ZnCr

2.2 N·m (19 lb in) 4.5 N·m (40 lb in) 7.5 N·m (66 lb in) 18 N·m (163 lb in)

3.2 N·m (28 lb in) 6.4 N·m (57 lb in) 11 N·m (96 lb in) 26 N·m (234 lb in)

M10

37 N·m (27 lb ft)

M12

64 N·m (47 lb ft)

M16 M20 M24

158 N·m (116 lb ft) 319 N·m (235 lb ft) 551 N·m (410 lb ft)

2.9 N·m (26 lb in) 5.9 N·m (52 lb in) 10 N·m (89 lb in) 25 N·m (217 lb in) 49 N·m (36 lb ft) 85 N·m (63 lb ft) 210 N·m (155 lb ft) 425 N·m (313 lb ft) 735 N·m (500 lb ft)

52 N·m (38 lb ft) 91 N·m (67 lb ft) 225 N·m (166 lb ft) 440 N·m (325 lb ft) 762 N·m (560 lb ft)

4.2 N·m (37 lb in) 8.5 N·m (75 lb in) 15 N·m (128 lb in) 35 N·m (311 lb in) 70 N·m (51 lb ft) 121 N·m (90 lb ft) 301 N·m (222 lb ft) 587 N·m (433 lb ft) 1016 N·m (750 lb ft)

LOCKNUT CL.8 W/CL8.8 BOLT

2 N·m (18 lb in) 4 N·m (36 lb in) 6.8 N·m (60 lb in) 17 N·m (151 lb in) 33 N·m (25 lb ft) 58 N·m (43 lb ft) 143 N·m (106 lb ft) 290 N·m (214 lb ft) 501 N·m (370 lb ft)

LOCKNUT CL.10 W/CL10.9 BOLT 2.9 N·m (26 lb in) 5.8 N·m (51 lb in) 10 N·m (89 lb in) 24 N·m (212 lb in) 48 N·m (35 lb ft) 83 N·m (61 lb ft) 205 N·m (151 lb ft) 400 N·m (295 lb ft) 693 N·m (510 lb ft)

NOTE: M4 through M8 hardware torque specifications are shown in pound-inches. M10 through M24 hardware torque specifications are shown in pound-feet.

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INTRODUCTION

METRIC FLANGED HARDWARE NOM. SIZE

CLASS 8.8 BOLT and CLASS 8 NUT PLATED W/ZnCr

UNPLATED M4 M5 M6 M8

2.4 N·m (21 lb in) 4.9 N·m (43 lb in) 8.3 N·m (73 lb in) 20 N·m (179 lb in)

M10

40 N·m (30 lb ft)

M12

70 N·m (52 lb ft)

M16 M20 M24

174 N·m (128 lb ft) 350 N·m (259 lb ft) 607 N·m (447 lb ft)

3.2 N·m (28 lb in) 6.5 N·m (58 lb in) 11 N·m (96 lb in) 27 N·m (240 lb in) 54 N·m (40 lb ft) 93 N·m (69 lb ft) 231 N·m (171 lb ft) 467 N·m (345 lb ft) 809 N·m (597 lb ft)

CLASS 10.9 BOLT and CLASS 10 NUT

UNPLATED 3.5 N·m (31 lb in) 7.0 N·m (62 lb in) 12 N·m (105 lb in) 29 N·m (257 lb in) 57 N·m (42 lb ft) 100 N·m (74 lb ft) 248 N·m (183 lb ft) 484 N·m (357 lb ft) 838 N·m (618 lb ft)

4.6 N·m (41 lb in) 9.4 N·m (83 lb in) 16 N·m (141 lb in) 39 N·m (343 lb in) 77 N·m (56 lb ft) 134 N·m (98 lb ft) 331 N·m (244 lb ft) 645 N·m (476 lb ft) 1118 N·m (824 lb ft)

Metric Hex head and carriage bolts, classes 5.6 and up

1

1. Manufacturer's Identification 2. Property Class

Metric Hex nuts and locknuts, classes 05 and up

20083681

2

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LOCKNUT CL.10 W/CL10.9 BOLT

2.2 N·m (19 lb in) 4.4 N·m (39 lb in) 7.5 N·m (66 lb in) 18 N·m (163 lb in)

3.1 N·m (27 lb in) 6.4 N·m (57 lb in) 11 N·m (96 lb in) 27 N·m (240 lb in)

PLATED W/ZnCr

IDENTIFICATION

20083680

LOCKNUT CL.8 W/CL8.8 BOLT

37 N·m (27 lb ft) 53 N·m (39 lb ft) 63 N·m (47 lb ft) 91 N·m (67 lb ft) 158 N·m (116 lb ft) 318 N·m (235 lb ft) 552 N·m (407 lb ft)

226 N·m (167 lb ft) 440 N·m (325 lb ft)

INTRODUCTION

1. Manufacturer's Identification 2. Property Class 3. Clock Marking of Property Class and Manufacturer's Identification (Optional), i.e. marks 60° apart indicate Class 10 properties, and marks 120° apart indicate Class 8.

INCH NON-FLANGED HARDWARE NOMINAL SIZE

SAE GRADE 5 BOLT and NUT UNPLATED or PLATED SILVER

1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1

SAE GRADE 8 BOLT and NUT

UNPLATED PLATED W/ZnCr or PLATED GOLD SILVER

LOCKNUT GrB W/ Gr5 BOLT

LOCKNUT GrC W/ Gr8 BOLT

PLATED W/ZnCr GOLD

12 N·m 16 N·m 8 N·m (71 lb 11 N·m (97 lb (106 lb in) (142 lb in) in) in) 17 N·m 23 N·m 24 N·m 32 N·m (150 lb in) (204 lb in) (212 lb in) (283 lb in) 40 N·m 43 N·m (31 lb 57 N·m (42 lb 30 N·m (22 lb (30 lb ft) ft) ft) ft) 65 N·m 48 N·m (36 lb 68 N·m (50 lb 91 N·m (67 lb (48 lb ft) ft) ft) ft) 98 N·m 104 N·m 139 N·m 74 N·m (54 lb (73 lb ft) (77 lb ft) (103 lb ft) ft) 107 N·m 142 N·m 150 N·m 201 N·m (79 lb ft) (105 lb ft) (111 lb ft) (148 lb ft) 147 N·m 196 N·m 208 N·m 277 N·m (108 lb ft) (145 lb ft) (153 lb ft) (204 lb ft) 261 N·m 348 N·m 369 N·m 491 N·m (193 lb ft) (257 lb ft) (272 lb ft) (362 lb ft) 420 N·m 561 N·m 594 N·m 791 N·m (310 lb ft) (413 lb ft) (438 lb ft) (584 lb ft) 630 N·m 841 N·m 890 N·m 1187 N·m (465 lb ft) (620 lb ft) (656 lb ft) (875 lb ft)

12.2 N·m (109 lb in) 17.5 N·m (155 lb 25 N·m (220 lb in) in)

8.5 N·m (75 lb in)

31 N·m (23 lb ft) 44 N·m (33 lb ft) 50 N·m (37 lb ft) 71 N·m (53 lb ft) 108 N·m (80 lb ft) 156 N·m (115 lb 111 N·m (82 lb ft) ft) 153 N·m (113 lb 215 N·m (159 lb ft) ft) 271 N·m (200 lb 383 N·m (282 lb ft) ft) 437 N·m (323 lb 617 N·m (455 lb ft) ft) 654 N·m (483 lb 924 N·m (681 lb ft) ft) 76 N·m (56 lb ft)

NOTE: For Imperial Units, 1/4 in and 5/16 in hardware torque specifications are shown in pound-inches. 3/8 in through 1 in hardware torque specifications are shown in pound-feet.

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INTRODUCTION

INCH FLANGED HARDWARE NOMSAE GRADE 5 BOLT and SAE GRADE 8 BOLT and INAL NUT NUT SIZE PLATED UNPLATED PLATED UNPLATED W/ZnCr or PLATED W/ZnCr or PLATED GOLD SILVER GOLD SILVER 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1

9 N·m (80 lb in) 19 N·m (168 lb in) 33 N·m (25 lb ft) 53 N·m (39 lb ft) 81 N·m (60 lb ft) 117 N·m (86 lb ft) 162 N·m (119 lb ft) 287 N·m (212 lb ft) 462 N·m (341 lb ft) 693 N·m (512 lb ft)

LOCKNUT GrG W/ Gr8 BOLT

LOCKNUT GrF W/ Gr5 BOLT

12 N·m (106 lb 13 N·m (115 lb 17 N·m (150 lb 8 N·m (71 lb in) in) in) in) 25 N·m (221 lb 26 N·m (230 lb 35 N·m (310 lb 17 N·m (150 lb in) in) in) in) 44 N·m (33 lb 47 N·m (35 lb 63 N·m (46 lb 30 N·m (22 lb ft) ft) ft) ft) 71 N·m (52 lb 75 N·m (55 lb 100 N·m (74 lb 48 N·m (35 lb ft) ft) ft) ft) 153 N·m 108 N·m (80 lb 115 N·m (85 lb 74 N·m (55 lb ft) (113 lb ft) ft) ft) 156 N·m 165 N·m 221 N·m 106 N·m (78 lb ft) (115 lb ft) (122 lb ft) (163 lb ft) 216 N·m 228 N·m 304 N·m 147 N·m (108 lb (159 lb ft) (168 lb ft) (225 lb ft) ft) 383 N·m 405 N·m 541 N·m 261 N·m (193 lb (282 lb ft) (299 lb ft) (399 lb ft) ft) 617 N·m 653 N·m 871 N·m 421 N·m (311 lb (455 lb ft) (482 lb ft) (642 lb ft) ft) 925 N·m 979 N·m 1305 N·m 631 N·m (465 lb (682 lb ft) (722 lb ft) (963 lb ft) ft)

12 N·m (106 lb in) 24 N·m (212 lb in) 43 N·m (32 lb ft) 68 N·m (50 lb ft) 104 N·m (77 lb ft) 157 N·m (116 lb ft) 207 N·m (153 lb ft) 369 N·m (272 lb ft) 594 N·m (438 lb ft) 890 N·m (656 lb ft)

IDENTIFICATION Inch Bolts and free-spinning nuts

20083682

3

Grade Marking Examples 1 2 3

Grade 2 - No Marks Grade 5 - Three Marks Grade 8 - Five Marks

SAE Grade Identification 4 Grade 2 Nut - No Marks 5 Grade 5 Nut - Marks 120° Apart 6 Grade 8 Nut - Marks 60° Apart

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INTRODUCTION

Inch Lock Nuts, All Metal (Three optional methods)

20090268

4

Grade Identification Grade Grade A Grade B Grade C

Corner Marking Method (1) No Notches One Circumferential Notch Two Circumferential Notches

Flats Marking Method (2) No Mark Letter B Letter C

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Clock Marking Method (3) No Marks Three Marks Six Marks

INTRODUCTION

Torque - Standard torque data for hydraulic connections General information • Hydraulic connections require a minimum assembly torque in order to provide zero leakage at rated pressure with adequate fatigue resistance. Over-torquing of a hydraulic connection can also lead to leakage or failure. For some connections, CASE CONSTRUCTION requires a different torque value than is listed in the ISO and SAE standards.

• The torque values in this document should be used whenever possible or applicable.

NOTICE: Always follow the instructions in this manual for specific torque values when you service components.

The information in this section is for general guidance only when a procedure contains no specific torque value.

Tolerance • The tolerance for all torque values is ± 10%. This tolerance must include all assembly variation, not only the torque wrench repeatability.

Lubrication Application of grease or other lubricants to hydraulic connectors should be avoided. If clean hydraulic oil is already on the connection, it is not required to remove the oil. Generally, application of grease: • May cause a significant change in the torque required to properly tighten the connection.

• May reduce the connection’s resistance to vibration.

• Excessive grease may displace an elastomer seal during tightening.

• Grease extrusion when connection is tightened may be mistaken for leakage.

CASE CONSTRUCTION products generally use O-Ring Boss (ORB) connectors that have Teflon™-coated O-rings, eliminating the need for O-ring lubrication during installation. For connections which are made into aluminum manifolds or with stainless steel connectors, it may be required to apply a lubricant to prevent galling.

Use of LOCTITE® and other thread-locking compounds is prohibited. These compounds: • May cause a significant change in the torque required to properly tighten the connections.

• Reduce the serviceability of the joint.

• May prevent the O-ring from properly sealing if the compound gets on the O-ring.

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INTRODUCTION

Torque values for metric O-Ring Boss (ORB) port connections

Metric thread M8 x 1 M10 x 1 M12 x 1.5 M14 x 1.5 M16 x 1.5 M18 x 1.5 M22 x 1.5 M27 x 2 M30 x 2 M33 x 2 M42 x 2 M48 x 2 M60 x 2

S-Series * Ferrous Non-Ferrous N·m (lb ft) ± 10% N·m (lb ft) ± 10% 10.5 (7.7) 21 (15.5) 37 (27.3) 47 (34.7) 58 (42.8) 74 (54.6) 105 (77.4) 178 (131.3) 225 (166) 325 (239.7) 345 (254.5) 440 (324.5) 525 (387.2)

L-Series ** Ferrous Non-Ferrous N·m (lb ft) ± 10% N·m (lb ft) ± 10%

6.3 (4.6) 12.5 (9.2) 22 (16.2) 28 (20.7) 35 (25.8) 44 (32.5) 63 (46.5) 107 (78.9) 135 (99.6) 195 (143.8) 207 (152.7) 264 (194.7) 315 (232.3)

8.5 (6.3) 15.5 (11.4) 27 (19.9) 37 (27.3) 42 (31) 47 (34.7) 63 (46.5) 105 (77.4) 136 (100.3) 168 (123.9) 220 (162.3) 273 (201.4) 330 (243.4)

5 (3.7) 9.3 (6.9) 16 (11.8) 22 (16.2) 25 (18.4) 28 (20.7) 38 (28) 63 (46.5) 82 (60.5) 101 (74.5) 132 (97.4) 164 (121) 198 (146)

* S-Series connectors are used with O-Ring Face Seals (ORFS). ** L-Series connectors are used with 37° flare.

Torque values for metric O-Ring Boss (ORB) port plugs

Ferrous

Non-ferrous

Metric thread

Internal hex N·m (lb ft) ± 10%

External hex N·m (lb ft) ± 10%

N·m (lb ft) ± 10%

M8 x 1 M10 x 1 M12 x 1.5 M14 x 1.5 M16 x 1.5 M18 x 1.5 M22 x 1.5 M27 x 2 M30 x 2 M33 x 2 M42 x 2 M48 x 2 M60 x 2

8.5 (6.3) 16 (11.8) 23 (17) 47 (34.7) 58 (42.8) 74 (54.6) 105 (77.4) 178 (131.3) 225 (166) 325 (239.7) 345 (254.5) 440 (324.5) 525 (387.2)

10.5 (7.7) 21 (15.5) 37 (27.3) 47 (34.7) 58 (42.8) 74 (54.6) 105 (77.4) 178 (131.3) 225 (166) 325 (239.7) 345 (254.5) 440 (324.5) 525 (387.2)

6.3 (4.6) 12.5 (9.2) 22 (16.2) 28 (20.7) 35 (25.8) 44 (32.5) 63 (46.5) 107 (78.9) 135 (99.6) 195 (143.8) 207 (152.7) 264 (194.7) 315 (232.3)

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INTRODUCTION

Torque values for port connections (British Standard Pipe Parallel (BSPP) thread ports and stud ends)

Metric tube Outside Diameter (OD) mm (in) BSPP thread G- Gas; A- medium coarse threads G 1/8 A G 1/4 A

G 3/8 A

S-Series *

L-Series **

– 6 (0.236) or 8 (0.315) 10 (0.394) or 12 (0.472)

6 (0.236) 8 (0.315) or 10 (0.394)

G 1/2 A

16 (0.630)

G 3/4 A G1A G 1 1/4 A G 1 1/2 A

20 (0.787) 25 (0.984) 30 (1.181) 38 (1.496)

12 (0.472) 15 (0.591) or 18 (0.709) 22 (0.866) 28 (1.102) 35 (1.378) 42 (1.654)

Ferrous

Non-Ferrous

S-Series N·m (lb ft) ± 10%

L-Series N·m (lb ft) ± 10%

S-Series N·m (lb ft) ± 10%

L-Series N·m (lb ft) ± 10%

–

21 (15.5)

–

12.5 (9.2)

63 (46.5)

53 (39.1)

38 (28)

32 (23.6)

95 (70.1)

84 (62)

57 (42)

50 (36.9)

136 (100.3)

105 (77.4)

82 (60.5)

63 (46.5)

210 (154.9) 400 (295) 525 (387.2) 660 (486.8)

210 (154.9) 400 (295) 525 (387.2) 660 (486.8)

126 (92.9) 240 (177) 315 (232.3) 396 (292.1)

126 (92.9) 240 (177) 315 (232.3) 396 (292.1)

* S-Series connectors are used with O-Ring Face Seals (ORFS). ** L-Series connectors are used with 37° flare.

Torque values for metric port connections (Metric face-seal ports and stud ends)

Metric tube Outside Diameter (OD) mm (in) Metric thread

S-Series *

M10 x 1 M12 x 1.5 M14 x 1.5 M16 x 1.5 M18 x 1.5 M20 x 1.5 M22 x 1.5 M26 x 1.5 M27 x 1.2 M33 x 2 M42 x 2 M48 x 2

– 4 (0.157) 5 (0.197) 7 (0.276) 8 (0.315) 10 (0.394) 12 (0.472) – 16 (0.630) 20 (0.787) 25 (0.984) 32 (1.260)

Ferrous

Non-Ferrous

L-Series **

S-Series N·m (lb ft) ± 10%

L-Series N·m (lb ft) ± 10%

S-Series N·m (lb ft) ± 10%

L-Series N·m (lb ft) ± 10%

4 (0.157) 6 (0.236) 7 (0.276) 9 (0.354) 11 (0.433) – 14 (0.551) 18 (0.709) – 23 (0.906) 30 (1.181) 36 (1.417)

– 47 (34.7) 63 (46.5) 84 (62) 105 (77.4) 147 (108.4) 158 (116.5) – 210 (154.9) 400 (295) 525 (387.2) 630 (464.7)

21 (15.5) 32 (23.6) 53 (39.1) 63 (46.5) 84 (62) – 147 (108.4) 210 (154.9)

– 28 (20.7) 38 (28) 50 (36.9) 63 (46.5) 88 (64.9) 95 (70.1) – 126 (92.9) 240 (177) 315 (232.3) 396 (292.1)

12.5 (9.2) 19 (14) 32 (23.6) 38 (28) 50 (36.9) – 88 (64.9) 126 (92.9) – 240 (177) 315 (232.3) 396 (292.1)

* S-Series connectors are used with O-Ring Face Seals (ORFS). ** L-Series connectors are used with 37° flare.

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400 (295) 525 (387.2) 630 (464.7)

INTRODUCTION

Torque values for Inch O-Ring Boss (ORB) port non-adjustable connections

SAE dash size

UN/UNF thread size

Inch tube OD mm (in)

2 3 4 5 6 8 10 12 14 16 20 24 32

5/16-24 3/8-24 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

3.18 (0.125) 4.76 (0.187) 6.35 (0.250) 7.94 (0.313) 9.52 (0.375) 12.7 (0.500) 15.88 (0.625) 19.05 (0.750) 22.22 (0.875) 25.4 (1.000) 31.75 (1.250) 38.1 (1.500) 50.8 (2.000)

S-Series * NonFerrous Ferrous N·m (lb ft) N·m (lb ft) ± 10% ± 10%

L-Series ** NonFerrous Ferrous N·m (lb ft) N·m (lb ft) ± 10% ± 10%

– 15.5 (11.4) 37 (27.3) 42 (31) 47 (34.7) 89 (65.6) 121 (89.2) 178 (131.3) 225 (166) 283 (208.7) 300 (221.3) 388 (286.2) 388 (286.2)

8.5 (6.3) 10.5 (7.7) 19 (14) 26 (19.2) 32 (23.6) 53 (39.1) 63 (46.5) 100 (73.8) 131 (96.6) 156 (115.1) 210 (154.9) 220 (162.3) 315 (232.3)

– 9.3 (6.9) 22 (16.2) 25 (18.4) 28 (20.7) 53 (39.1) 73 (53.8) 107 (78.9) 135 (99.6) 170 (125.4) 180 (132.8) 233 (171.9) 233 (171.9)

5 (3.7) 6.3 (4.6) 11.5 (8.5) 15.5 (11.4) 19 (14) 32 (23.6) 38 (28) 60 (44.3) 79 (58.3) 94 (69.3) 126 (92.9) 132 (97.4) 189 (139.4)

* S-Series connectors are used with O-Ring Face Seals (ORFS). ** L-Series connectors are used with 37° flare.

Torque values for inch O-Ring Boss (ORB) port adjustable connections

SAE dash size

UN/UNF thread size

Inch tube OD mm (in)

2 3 4 5 6 8 10 12 14 16 20 24 32

5/16-24 3/8-24 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

3.18 (0.125) 4.76 (0.187) 6.35 (0.250) 7.94 (0.313) 9.52 (0.375) 12.7 (0.500) 15.88 (0.625) 19.05 (0.750) 22.22 (0.875) 25.4 (1.000) 31.75 (1.250) 38.1 (1.500) 50.8 (2.000)

S-Series * NonFerrous Ferrous N·m (lb ft) N·m (lb ft) ± 10% ± 10%

L-Series ** NonFerrous Ferrous N·m (lb ft) N·m (lb ft) ± 10% ± 10%

– 10.5 (7.7) 21 (15.5) 42 (31) 47 (34.7) 89 (65.6) 121 (89.2) 178 (131.3) 225 (166) 285 (210.2) 300 (221.3) 388 (286.2) 388 (286.2)

8.5 (6.3) 10.5 (7.7) 19 (14) 26 (19.2) 32 (23.6) 53 (39.1) 63 (46.5) 100 (73.8) 131 (96.6) 156 (115.1) 210 (154.9) 220 (162.3) 315 (232.3)

* S-Series connectors are used with O-Ring Face Seals (ORFS). ** L-Series connectors are used with 37° flare.

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– 9.3 (6.9) 21 (15.5) 25 (18.4) 28 (20.7) 53 (39.1) 73 (53.8) 107 (78.9) 135 (99.6) 170 (125.4) 180 (132.8) 233 (171.9) 233 (171.9)

5 (3.7) 6.3 (4.6) 11.5 (8.5) 15.5 (11.4) 19 (14) 32 (23.6) 38 (28) 60 (44.3) 79 (58.3) 94 (69.3) 126 (92.9) 132 (97.4) 189 (139.4)

INTRODUCTION

Torque values for inch O-Ring Boss (ORB) port plugs

SAE dash size

UN/UNF thread size

2 3 4 5 6 8 10 12 14 16 20 24 32

5/16-24 3/8-24 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

Ferrous External hex Internal hex N·m (lb ft) N·m (lb ft) ± 10% ± 10% 7.5 (5.5) 14.5 (10.7) 21 (15.5) 28 (20.7) 47 (34.7) 89 (65.6) 116 (85.6) 176 (129.8) 247 (182.2) 284 (209.5) 357 (263.3) 441 (325.3) 536 (395.3)

12.5 (9.2) 21 (15.5) 37 (27.3) 42 (31) 47 (34.7) 89 (65.6) 116 (85.6) 176 (129.8) 247 (182.2) 284 (209.5) 357 (263.3) 441 (325.3) 536 (395.3)

Non-Ferrous N·m (lb ft) ± 10% 7.5 (5.5) 12.5 (9.2) 22 (16.2) 25 (18.4) 28 (20.7) 53 (39.1) 70 (51.6) 106 (78.2) 148 (109.2) 170 (125.4) 214 (157.8) 265 (195.5) 322 (237.5)

Torque values for four-bolt flange connections (Metric Screws, Class 10.9)

Metric size mm

Imperial size in

Screw code 61

Code 61 N·m (lb ft) ± 10%

13 19 25

1/2 3/4 1

M8 x 1.25 M10 x 1.5 M10 x 1.5

34 (25.1) 74 (54.6) 74 (54.6)

32

1-1/4

M10 x 1.5

74 (54.6)

38 51 64 76 89 102 127

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

M12 x 1.75 M12 x 1.75 M12 x 1.75 M16 x 2 M16 x 2 M16 x 2 M16 x 2

137 (101) 137 (101) 137 (101) 310 (228.6) 310 (228.6) 310 (228.6) 310 (228.6)

Screw code 62

Code 62 N·m (lb ft) ± 10%

M8 x 1.25 M10 x 1.5 M12 x 1.75 M12 x 1.75 M14 x 1.5 M16 x 2 M20 x 2.5 M24 x 3 M30 x 3.5 – – –

34 (25.1) 74 (54.6) 137 (101) 137 (101) 189 (139.4) 310 (228.6) 575 (424.1) 575 (424.1) 680 (501.5) – – –

Screw code 62

Code 62 N·m (lb ft) ± 10%

M8 x 1.25 M10 x 1.5 M12 x 1.75 M12 x 1.75 M14 x 1.5 M16 x 2 M20 x 2.5 M24 x 3 M30 x 3.5 – – –

29 (21.4) 57(42) 100 (73.8) 100 (73.8) 160 (118) 250 (184.4) 500 (368.8) 575 (424.1) 680 (501.5) – – –

Torque values for four-bolt flange connections (Metric Screws, Class 8.8)

Metric size mm

Imperial size in

Screw code 61

Code 61 N·m (lb ft) ± 10%

13 19 25

1/2 3/4 1

M8 x 1.25 M10 x 1.5 M10 x 1.5

29 (21.4) 57(42) 57(42)

32

1-1/4

M10 x 1.5

57(42)

38 51 64 76 89 102 127

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

M12 x 1.75 M12 x 1.75 M12 x 1.75 M16 x 2 M16 x 2 M16 x 2 M16 x 2

100 (73.8) 100 (73.8) 100 (73.8) 250 (184.4) 250 (184.4) 250 (184.4) 250 (184.4)

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INTRODUCTION

Torque values for four-bolt flange connections (Inch Screws, Grade 8)

Metric size mm

Imperial size in

Screw code 61

Code 61 N·m (lb ft) ± 10%

Screw code 62

Code 62 N·m (lb ft) ± 10%

13 19 25 32 38 51 64 76 89 102 127

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

5/16-18 3/8-16 3/8-16 7/16-14 1/2-13 1/2-13 1/2-13 5/8-11 5/8-11 5/8-11 5/8-11

34 (25.1) 63 (46.5) 63 (46.5) 97 (71.5) 158 (116.5) 158 (116.5) 158 (116.5) 310 (228.6) 310 (228.6) 310 (228.6) 310 (228.6)

5/16-18 3/8-16 7/16-14 1/2-13 5/8-11 3/4-10 – – – – –

34 (25.1) 63 (46.5) 97 (71.5) 158 (116.5) 310 (228.6) 473 (348.9) – – – – –

Tapered thread connection tightening

British Standard Pipe Taper (BSPT) thread size (inch)

National Pipe Thread Fuel (NPTF) thread size (inch)

1/8-28 1/4-19 3/8-19 1/2-14 3/4-14 1-11 1-1/4-11 1-1/2-11 2-11

1/8-27 1/4-18 3/8-18 1/2-14 3/4-14 1-11 1/2 1-1/4-11 1/2 1-1/2-11 1/2 2-11 1/2

Turns from finger tight 2 2 2 2 2 1.5 1.5 1.5 1.5

-

3 3 3 3 3 2.5 2.5 2.5 2.5

Torque values for banjo bolt connections (Copper washer style)

Bolt thread (metric)

Hex size (mm)

Torque N·m (lb ft) ± 10%

M8 x 1.25 M10 x 1.25 M12 x 1.5 M14 x 1.5 M16 x 1.5 M18 x 1.5 M20 x 1.5 M22 x 1.5 M24 x 1.5

13 17 17 19 22 24 27 32 32

13 (9.6) 16 (11.8) 40 (29.5) 45 (33.2) 48 (35.4) 50 (36.9) 73 (53.8) 73 (53.8) 73 (53.8)

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INTRODUCTION

Torque values for O-Ring Face Seals (ORFS) connections

SAE dash size

UN/UNF thread size

4 5 6 8 10 12 14 16 20 24

9/16-18 5/8-18 11/16-16 13/16-16 1-14 1-3/16-12 1-5/16-12 1-7/16-12 1-11/16-12 2-12

Inch tube OD (mm)

Metric tube OD (mm)

Hex size (mm) (Reference only)

* Swivel nut torque N·m (lb ft) ± 10%

** Swivel nut torque N·m (lb ft) ± 10%

6.35 7.94 9.52 12.7 15.88 19.05 22.23 25.4 31.75 38.1

6 8 10 12 16 20 22 25 30 38

17 19 22 24 30 36 41 41 50 60

27 (19.9) 34 (25.1) 44 (32.5) 65 (47.9) 100 (73.8) 150 (110.6) 163 (120.2) 210 (154.9) *** 280 (206.5) *** 375 (276.6) ***

27 (19.9) 34 (25.1) 44 (32.5) 65 (47.9) 100 (73.8) 131 (96.6) 131 (96.6) 131 (96.9) 178 (131.3) 210 (154.9)

* High/Medium-pressure applications > 50 bar (725 psi). ** Low-pressure applications < 50 bar (725 psi). *** It is recommended to use a four-bolt flange connection instead of O-Ring Face Seals (ORFS) sizes "16" and up.

Torque values for 37° flare connections - Joint Industry Council (JIC)

SAE dash size

UN/UNF thread size

Metric tube OD (mm)

Inch tube OD (mm)

Swivel nut torque N·m (lb ft) ± 10%

2 3 4 5 6 8 10 12 14 16 20 24 32

5/16-24 3/8-24 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

– – 6 8 10 12 16 20 – 25 30/32 38 50

3.18 4.76 6.35 7.94 9.52 12.7 15.88 19.05 22.22 25.4 31.75 38.1 50.8

8.25 (6.1) 11.5 (8.5) 15.5 (11.4) 20 (14.8) 25 (18.4) 52 (38.4) 81 (59.7) 112 (82.6) 133 (98.1) 155 (114.3) 180 (132.8) 225 (166) 348 (256.7)

Torque values for 30° flare, 60° cone connections

Nominal size (mm)

British Standard Pipe Parallel (BSPP) thread size

Hex size (mm)

Swivel nut torque N·m (lb ft) ± 10%

5, 6, 6.3 8, 9, 10 12, 12.5 15, 16, 19 25 31.5, 32 38 50, 51

G 1/4 G 3/8 G 1/2 G 3/4 G1 G 1-1/4 G 1-1/2 G2

17 19 22 30 36 46 50 65

25 (18.4) 34 (25.1) 64 (47.2) 132 (97.4) 196 (144.6) 225 (166) 255 (188.1) 316 (223.1)

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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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INTRODUCTION

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

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

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

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

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

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

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

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

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

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

WARNING Battery acid causes burns. Batteries contain sulfuric acid.

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

Failure to comply could result in death or serious injury.

W0111A

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

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

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INTRODUCTION

Maintenance chart Replace Lubricate Change fluid Check

Cleaning Bleed Adjust

Maintenance action Every 20 hours of operation (daily) x Check the engine oil level x Check the engine coolant level x Check the hydraulic oil level x Check the engine fan x Check the crankcase breather pipe x Air filter dust valve x Check the alarm and control instruments Initial 100 hours x Wheel bolt torque x Change the travel transmission fluid Every 100 hours of operation or weekly x Tire pressure Every 250 hours x Coolers check x Check the air filter sensor x Machine lubrication x Check the vibrator oil level x Check the travel transmission fluid level x Check the pad foot segments Initial 500 hours x Change the vibrator oil Every 500 hours of operation or every six months x Change the engine oil x Replace fuel filter x Replace the air filter elements x Replace cab ventilation and heating filters x Checking the engine coolant level x Electrical wiring check x Replace the air filter elements for the air conditioning x Wheel bolt torque Every 1000 hours of operation or annually x Check the battery x Check the engine belt x Change the travel transmission fluid x Check the air conditioning compressor mounting x Check the damping system x Air cooler Every 2000 hours of operation or annually x Change the vibrator oil x Clean the air conditioning system x Change hydraulic oil and replacing the filter x Change the engine coolant As required x Bleed the fuel system x Clean the water separator x Cleaning the radiators x Adjust the scrapers x Check bolted connections x Clean the machine 48150518 26/02/2018

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INTRODUCTION

Basic instructions - Towing a disabled machine WARNING Transport hazard!

Follow ALL of the precautions listed below.

Failure to comply could result in death or serious injury.

W1104A

• Before releasing the parking brake, secure the machine with wheel chocks!

• Do not touch hot parts of the machine. Risk of burning!

• Do not start the engine while the machine is being towed!

• Do not tow the machine for a distance over 300 m (984.3 ft).

• The maximum speed limit while towing the machine is 2 km/h (1.2 mph).

• Due to leakage, the pressure in the brakes may drop during the course of towing.

• Regularly check that the machine brakes do not become hot while towing the machine.

NOTICE: A sunk machine can be towed for a short distance if the engine is running and the travel drive and steering are operational. The operator on a towed machine must steer the machine in the direction of towing. Unless the engine works, there is a fault in the hydraulic system or the travel pump is malfunctioning, you must release the parking brake and close the hydraulic circuit. See the following pages to release the parking brake and close the hydraulic circuit. When the brakes are released and the hydraulic circuit for travel is closed, all of the brakes are disabled!

NOTE: These are general requirements for safe towing of a damaged machine under normal conditions. Consult with your dealer regarding any and all other situations that may occur while towing the machine.

NOTICE: The machine is not intended to tow other equipment.

The machine is equipped with the following for towing: Two eyelets (1) on the drum frames plus a front towing attachment (2) (optional).

SS12J338

1

SS12J339

2

Rear towing attachment.

NOTICE: Use both lugs when towing the machine.

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INTRODUCTION

Disengage the parking brake Remove the hose (1) from the clamp (2).

RAIL14COM0162AA

3

RAIL14COM0162AA

4

RAIL14COM0161AA

5

RAIL14COM0162AA

6

Disconnect the hose (1) from the tube (2).

Remove the cap (2) from the hose (1).

Connect the hose (2) to the tube (1).

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INTRODUCTION

Cap the hose (1) and secure it with the clamp (2).

RAIL14COM0162AA

7

SS12J342

8

SS12J343

9

Close the travel hydraulic circuit Hold the outer portion of the multipurpose valve on the drive pump. Turn the inner portion of the valve three full turns counter-clockwise. Repeat the procedure on the other multipurpose valve.

Have the assistant insert the key into the ignition and turn to position I. The parking lamp should turn on. Have the assistant monitor the parking brake lamp and notify you when the parking lamp turns off.

NOTE: This procedure is easier with the assistance of another person.

Remove the access panel below the operator platform.

Move the hand pump lever side to side. The pressure in the travel circuit will increase and release the parking brake. The assistant should notify you when the parking lamp turns off.

NOTE: This is normally used to raise or lower the cab or canopy.

SS12J313

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10

INTRODUCTION

Restoring to the original state Hold the outer portion of the multipurpose valve on the drive pump. Turn the inner portion of the valve three full turns clockwise. Repeat the procedure on the other multipurpose valve.

RAIL14COM0163AA

11

RAIL14COM0162AA

12

RAIL14COM0162AA

13

RAIL14COM0161AA

14

Remove the hose (1) from the clamp (2).

Disconnect the hose (1) from the tube (2).

Remove the cap (2) from the hose (1).

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INTRODUCTION

Connect the hose (2) to the tube (1).

RAIL14COM0162AA

15

RAIL14COM0162AA

16

SS12J343

17

Cap the hose (1). Secure the capped hose (1) with the clamp (2).

Insert the key into the ignition and turn to position I. The parking lamp should turn on.

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INTRODUCTION

Basic instructions WARNING Hazardous chemicals!

Battery electrolyte contains sulfuric acid. Contact with skin and eyes could result in severe irritation and burns. Always wear splash-proof goggles and protective clothing (gloves and aprons). Wash hands after handling.

Failure to comply could result in death or serious injury.

W0006A

WARNING Avoid injury!

Follow ALL of the precautions listed below.

Failure to comply could result in death or serious injury.

W1091A

• To connect the cables correctly to the battery of this machine, see the correct method illustrated on this page.

• Batteries contain sulfuric acid and during charging generate a highly explosive mixture of hydrogen and oxygen gases. Never use equipment that generates flames or sparks to check the electrolyte level.

• Do not connect the (–) cable to the (–) of the discharged battery of the machine being started! There is risk of strong sparking during the course of starting, followed by explosion of battery-generated gas.

• When removing the battery terminal for any reason, do not allow the negative and positive cables to touch or to make contact with the battery. Battery posts, terminals, and related accessories contain lead and lead compounds.

• Operate the starter from the operator seat only.

When using an auxiliary starting source, its power supply must have a starting voltage of 24 V .

Starting with jumper cables from a different machine 1. Connect one end of the (+) cable pole to the (+) pole of the discharged battery.

2. Connect the other end of the (+) cable pole to the (+) pole of the machine battery providing starting voltage.

3. Connect one end of the (-) pole to the (-) pole of the vehicle battery providing starting voltage.

4. Connect the other end of the (-) cable pole to a good frame ground or the engine block itself away from the discharged battery.

5. Start the engine of the disabled machine. See starting the engine in this manual.

6. Remove the (-) cable pole connection first and then the (+) cable pole cable connection last.

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RAIL17COM0110FA

1

INTRODUCTION

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

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

The following list includes some of these problems: • Cylinder rod seals that leak • Control valve spools that do not return to neutral • Movement of control valve spools is difficult • Hydraulic oil that becomes too hot • Pump gears, housing, and other parts that wear rapidly • Relief valves or check valves held open by dirt • Quick failure of components that have been repaired • Slow cycle times are slow. The machine does not have enough power.

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

There are two types of contamination: microscopic and visible.

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

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

Examples of problems caused by microscopic contamination: • Cylinder rod seals that leak • Control valve spools that do not return to neutral • The hydraulic system has a high operating temperature Visible contamination is foreign material that can be found by sight, touch, or odor. Visible contamination can cause a sudden failure of components.

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

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INTRODUCTION

General specification SV208D Weights D Operating weight of CECE with cab, ROPS Operating weight of CECE with cab Operating weight of CECE with platform, rail Operating load of CECE with cab, ROPS on front axis Operating load of CECE with cab, ROPS on rear axis Weight of half fluid capacities Operating weight of ISO 6016 with cab, ROPS Maximum weight with the cab, ROPS, accessories Maximum permitted weight according to ROPS Static linear load of front drum Cab weight Weight of ROPS / FOPS Weight of canopy Weight of canopy posts (version without ROPS) Weight of blade Weight of 3 padfoot segments Weight of tire filling 0 °C (32 °F) Weight of tire filling -25 °C (-13 °F)

HD

HT

PD

HDPD

HTPD

7240 kg (15961 lb)

7620 kg (16799 lb)

7090 kg (15631 lb)

7570 kg (16689 lb)

7030 kg (15498 lb)

7470 kg (16469 lb)

6940 kg (15300 lb)

7420 kg (16358 lb)

6880 kg (15168 lb)

7320 kg (16138 lb)

6790 kg (14969 lb)

7260 kg (16006 lb)

3990 kg (8796 lb)

4080 kg (8995 lb)

3250 kg (7165 lb)

3540 kg (7804 lb)

3970 kg (8752 lb)

4030 kg (8885 lb)

3120 kg (6878 lb)

3540 kg (7804 lb)

110 kg (243 lb)

7350 kg (16204 lb)

7730 kg (17042 lb)

7200 kg (15873 lb)

7680 kg (16932 lb)

9360 kg (20635 lb)

9740 kg (21473 lb)

8120 kg (17902 lb)

8600 kg (18960 lb)

13200 kg (29101 lb)

—

23.7 kg/cm (24.6 lb/in) 220 kg (485 lb) 290 kg (639 lb) 60 kg (132 lb)

60 kg (132 lb) 500 kg (1102 lb) —

1090 kg (2403 lb)

367 kg (809 lb)

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INTRODUCTION

Driving characteristics D Drive type Number of operating speeds Number of transport speeds Maximum transport speed Working speed 1 Working speed 2 Working speed 3 Climbing ability Climbing ability with vibration Lateral static stability Lateral stability during driving without vibration Lateral static stability during driving with vibration Maximum gradient when towing machine on slope Turning radius inner (edge) Turning radius outer (contour) Front approach slope Rear approach slope Number of driving axles Oscillation angle Angle of steering

HD

HT

PD

HDPD

HTPD

11.1 km/h (6.9 mph)

10.1 km/h (6.3 mph)

8.5 km/h (5.3 mph)

3.4 km/h (2.1 mph) 4.5 km/h (2.8 mph) 55%

3.0 km/h (1.9 mph) 3.7 km/h (2.3 mph) 60%

HDPD

HTPD

hydrostatic 3

1 11.4 km/h (7.1 mph)

10.0 km/h (6.2 mph)

8.4 km/h (5.2 mph)

2.5 km/h (1.6 mph) 3.6 km/h (2.2 mph) 5.1 km/h (3.2 mph) 45%

3.4 km/h (2.1 mph) 4.4 km/h (2.7 mph) 55%

3.0 km/h (1.9 mph) 3.6 km/h (2.2 mph) 60%

3.5 km/h (2.2 mph) 4.8 km/h (3.0 mph) 45% 40% 48.8%

25%

15%

60%

3200 mm (126 in) 5130 mm (202 in) 65% 46% 2 +/- 12 +/- 36

Steering D

HD

HT

Type of steering Steering control

PD Joint Hydraulic

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INTRODUCTION

D

HD

HT

Linear hydraulic motors

PD

HDPD

HTPD

PD

HDPD

HTPD

2

Axle D

HD

Maximum tire pressure Pattern of tires

HT

0.2 MPa (21.8 psi) UK 5 Diamond Traction tread tires 2

Number of tires Number of rear wheels Size of tires Type of tires Number of pads (Padfoot version only) Pad contact surface (Padfoot version only) Pad height (Padfoot version only)

2 14.9 x 24” Tubeless —

104

—

114.0 cm² (17.7 in²)

—

80.0 mm (3.1 in)

Brakes D

HD

D

HD

Operating Parking Emergency

HT

PD Hydrostatic Multiple-disc spring brake Multiple-disc spring brake

HDPD

HTPD

HT

HDPD

HTPD

HDPD

HTPD

Vibration Frequency I Frequency II Amplitude I Amplitude II Centrifugal force I Centrifugal force II Type of drive

PD 30 Hz 41 Hz 1.7 mm (0.067 in) 0.860 mm (0.034 in) 145 kN 130 kN Hydrostatic

Electrical D

HD

HT

Nominal voltage Battery capacity

PD 24 V 2 x 61 A·h

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INTRODUCTION

Capacities NOTE: All specifications are given according to Society of Automotive Engineers (SAE) standards or recommended practices where the specification applies.

Engine Oil type

CASE AKCELA UNITEK CJ-4 ENGINE OIL SAE 15W-40 10 L (2.64 US gal)

Oil exchange capacity with filter Cooling system Coolant type System coolant capacity Hydraulic system Oil type

CNH XHD HEAVY DUTY COOLANT / ANTI-FREEZE 28.0 L (7.4 US gal)

Capacity Fuel tank Capacity Vibratory drum Oil type

255.00 L (67.36 US gal)

CASE AKCELA HY-TRAN® ULTRA™ HYDRAULIC TRANSMISSION OIL 72.00 L (19.02 US gal)

CASE AKCELA UNITEK CJ-4 ENGINE OIL SAE 15W-40 6.70 L (1.77 US gal)

Capacity Drum transmission Oil type

CASE AKCELA GEAR LUBE 135 H EP 80W-90 for outdoor temperature -10.0 – 30.0 °C (14.0 – 86.0 °F) CASE AKCELA TRANSAXLE FLUID 80W-140 for outside temperature 20.0 – 45.0 °C (68.0 – 113.0 °F) 2.50 L (0.66 US gal)

Capacity Axle transmission Oil type

CASE AKCELA GEAR LUBE 135 H EP 80W-90 for outdoor temperature -10.0 – 30.0 °C (14.0 – 86.0 °F) CASE AKCELA TRANSAXLE FLUID 80W-140 for outside temperature 20.0 – 45.0 °C (68.0 – 113.0 °F) 2x 2.5 L (2 x 0.66 US gal)

Capacity Windshield washer tank Fluid type Capacity Tires

TUTELA PROFESSIONAL SC35 2.75 L (0.73 US gal) Air or liquid

Filling tires with water 0 °C (32 °F) Water 130.0 L (34.3 US gal)

Calcium chloride CaCI2 53.5 kg (117.9 lb)

Added weight 183.5 kg (404.5 lb)

Filling tires with water -25 °C (-13 °F) Water 65.0 l (17.2 US gal)

Calcium chloride CaCI2 145.2 kg (320.1 lb)

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Added weight 210 kg (463 lb)

INTRODUCTION

Dimension Dimensional diagram for SV 208D (with cab, ROPS frame and blade)

RAIL17COM0092FA

Smooth drum Padfoot drum Padfoot drum with blade

A 2690.0 mm (105.9 in) 2690.0 mm (105.9 in) 2690.0 mm (105.9 in)

D 1300 mm (51.2 in) 1240.0 mm (48.8 in) 1240.0 mm (48.8 in)

D1

G 385 mm (15.2 in) 1400.0 mm 385 mm (55.1 in) (15.2 in) 1400.0 mm 385 mm (55.1 in) (15.2 in) —

1

H1 2280.0 mm (89.8 in) 2280.0 mm (89.8 in) 2280.0 mm (89.8 in)

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L L1 5720.0 mm — (225.2 in) 5720.0 mm (225.2 in) 5720.0 mm 5630.0 mm (225.2 in) (221.7 in)

T 25 mm (1.0 in) 15.0 mm (0.6 in) 15.0 mm (0.6 in)

INTRODUCTION

RAIL17COM0093FA

G1 370.0 mm (14.6 in) 370.0 mm Padfoot drum (14.6 in) Padfoot drum with 370.0 mm (14.6 in) blade Smooth drum

H 2870.0 mm (113.0 in) 2870.0 mm (113.0 in) 2870.0 mm (113.0 in)

2

W 1680.0 mm (66.1 in) 1680.0 mm (66.1 in) 1680.0 mm (66.1 in)

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W1

W2

—

—

—

—

1875.0 mm (73.8 in)

2215.0 mm (87.2 in)

INTRODUCTION

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

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

MACHINE Type / Model & Designation Product Identification Number (PIN) Year of Build Engine Serial Number

RAIL14COM0348BA

1

SS13A883

2

SS13A882

3

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

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INTRODUCTION

Part identification - Engine serial number Engine serial number location.

SS12K516

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1

INTRODUCTION

Product identification - Machine orientation 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

Part identification - Machine components

RAIL17COM0076FA

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

Vibratory drum Drum frame Scraper Machine frame articulation joint Machine frame Axle Fuel tank Batteries Roll Over Protective System (ROPS) frame Hydraulic tank Cab or Canopy Hood Engine Radiator - Engine air cooler for intake manifold - Hydraulic systems cooler

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

1

Engine charge air cooler Driver’s machine controls Travel hydraulic pump Vibration hydraulic pump Control hydraulic pump Catalytic converter Air filter Padfoot segments (optional) Hydraulic oil pressure filter Fuel filter Fuel filter with a water separator Engine oil filter Air pre-filter (optional)

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SERVICE MANUAL Maintenance SV208D

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Contents Maintenance - 00

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

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Maintenance - 00 Start-up - 150

SV208D

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Contents Maintenance - 00 Start-up - 150

SERVICE Machine Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Maintenance - Start-up

Machine - Storing Short-term preservation and storage for 1-2 month NOTICE: Never start the engine during the course of storage. Prior to restoration of machine operation, wash the preservation agents away with a high-pressure jet of hot water combined with normal de-greasers while observing the Instructions for Use along with ecological guidelines. Carry out the de-waxing (de-conservation) and washing of the machine at places equipped with intercepting sumps to trap the rinsing water as well as de-waxing agents. Before starting operations again, wash machine with high-pressure hot water using ordinary de-greasing agent added as directed by the chemical manufacturer, while observing environmental regulations. Wash the machine in places with catch basins available to collect rinse water and chemicals.

• Wash and clean the entire machine carefully.

• Before parking the machine for its preservation and storage; warm up the engine to its operating temperature while running.

• Park the machine on a solid, flat surface at a safe place with no risk of natural disaster (floods, landslides, fire, etc.) to the machine.

In addition: • Repair spots with damaged paint.

• Lubricate all lubrication points, control cables, joints of the controls, etc.

• Confirm water fillings are drained..

• Check that the coolant has the required antifreeze properties.

• Check the state of accumulator charges; recharge if necessary.

• Apply preservative grease over the chrome surfaces of piston rods.

• We recommend protection of the machine against corrosion through spraying the preservation agent (applied spraying), particularly in places with potential of corrosion.

A machine treated like this will need no special preparation prior to its subsequent recommissioning.

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Maintenance - Start-up

Machine - Storing Machine preservation and storage for longer than 2 months When parking the machine, the same principles apply as for short-term preservation (see also page Machine - Storing (00.150) ).

In addition, the following are recommended: • Dismantle the accumulators, check their condition and store in a cool, dry room (recharge the accumulators regularly).

• Support the runner frame so the damping system shows minimal sag.

• Protect rubber elements by applying special preservation agent.

• Inflate the tires to the required pressure and protect them from direct sunlight. Apply preservation grease to the chrome surfaces of the piston rods.

• Preserve the machine via spraying with special agent, particularly at places of possible corrosion origin.

• Cover the engine suction and discharge ports with double polyethylene foil and secure this foil thoroughly with adhesive tape.

• Protect the headlights, external rear view mirrors and other elements with external wiring by spraying a special agent and wrapping in polyethylene foil.

• Preserve the engine as described in the engine manufacturer’s instruction manual – visibly mark that the engine has been preserved.

NOTE: When the machine is taken out of service because it is damaged beyond repair or has reached the end of it’s useful life, disassembly, scrapping, and/or recycling of components, fluids, etc. must be performed only by a qualified technician using service instructions and in compliance with local laws and regulations.

Pump fuel via feed hand pump on the engine (after prolonged shutdown of the machine).

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

3

Machine - Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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. © 2018 CNH Industrial America LLC. All rights reserved.

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

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

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

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

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

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SERVICE MANUAL Engine SV208D

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Contents Engine - 10

[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.310] Aftercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

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Engine - 10 Engine and crankcase - 001

SV208D

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Contents Engine - 10 Engine and crankcase - 001

SERVICE Engine Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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Engine - Engine and crankcase

Engine - Remove Prior operation: Hood - Remove (90.100) Prior operation: Aftercooler - Remove (10.310) 1. Disconnect and remove the hoses from the filter dehydrator.

Remove the hoses from the a/c compressor.

NOTE: Applicable only for machines with an air-conditioning system.

RAIL17COM0257AA

1

RAIL17COM0258AA

2

RAIL17COM0282AA

3

2. Disconnect the connector from the compressor.

3. Remove nuts from rubber-mounts of the cab.

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Engine - Engine and crankcase

4. Turn on the battery using the disconnect switch. Take off the cover of the cab lifting switch. Lift the cab using the switch.

RAIL17COM0283AA

4

RAIL17COM0280AA

5

RAIL17COM0281AA

6

5. Use the disconnect switch to disconnect the battery.

6. Remove the rubber gasket.

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Engine - Engine and crankcase

7. Disconnect the batteries.

Remove the bracket with batteries and put aside.

NOTE: First disconnect the terminal from the battery negative pole (black cable), then the terminal from the positive pole (red cable).

RAIL17COM0242AA

7

RAIL17COM0252AA

8

RAIL17COM0246AA

9

8. Remove the covers from the under carriage.

9. Drain the engine oil.

NOTE: The drained oil volume is 10.0 L (2.6 US gal).

10. Remove the drain hose from the oil tank.

RAIL17COM0272AA

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10

Engine - Engine and crankcase

11. Disconnect the hose (1) from the hydraulic tank, cover the outlets.

RAIL17COM0259AA

11

RAIL17COM0260AA

12

RAIL17COM0261AA

13

12. Use an appropriate container for capturing any leaking fluids under the cooling pump.

13. Remove the hoses (1) from the cooling pump. Disconnect the wiring from the alternator (2).

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Engine - Engine and crankcase

14. Remove the bracket with the relay from the engine.

RAIL17COM0262AA

14

RAIL17COM0263AA

15

RAIL17COM0264AA

16

15. Remove the cooling hose (1).

16. Disconnect the connector from the engine controller.

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Engine - Engine and crankcase

17. Disconnect the cable from the starter.

RAIL17COM0265AA

17

RAIL17COM0266AA

18

RAIL17COM0267AA

19

18. Disconnect the fuel overflow hose.

19. Remove the engine pre-heating wire.

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Engine - Engine and crankcase

20. Remove the heating hose from the clip.

RAIL17COM0268AA

20

RAIL17COM0269AA

21

RAIL17COM0270AA

22

21. Remove the heating hose from the engine.

22. Remove the heating hose from the engine.

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Engine - Engine and crankcase

23. Disconnect the engine ground connection.

RAIL17COM0271AA

23

RAIL17COM0273AA

24

24. Hang the pumps on a hoist.

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Engine - Engine and crankcase

25. Remove the nuts from the engine rubber mounts.

RAIL17COM0286AA

25

RAIL17COM0274AA

26

RAIL17COM0287AA

27

26. Remove the bolts (1) from the flange (2).

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Engine - Engine and crankcase

27. Mount lifting lugs on the engine. Hang the engine on appropriate lifting equipment.

RAIL17COM0275AA

28

RAIL17COM0276AA

29

RAIL17COM0277AA

30

28. Remove the clamp from the hydraulic tank.

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Engine - Engine and crankcase

29. Run the hoses from the linear hydraulic motor of the bonnet lifting through the exhaust elbow.

RAIL17COM0278AA

31

RAIL17COM0279AA

32

RAIL17COM0284AA

33

30. Slowly lift the motor from the frame.

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Engine - Engine and crankcase

Engine - Install 1. Slowly lower the engine into place.

RAIL17COM0284AA

1

RAIL17COM0286AA

2

RAIL17COM0274AA

3

2. Install the engine mounting bolts and nuts removed earlier.

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Engine - Engine and crankcase

3. Secure hoses with the clamp removed earlier, to the hydraulic tank.

RAIL17COM0277AA

4

RAIL17COM0275AA

5

RAIL17COM0287AA

6

4. Remove the lifting lugs installed earlier.

5. Install the bolts (1) removed earlier, onto the flange (2).

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Engine - Engine and crankcase

6. Connect the engine ground.

RAIL17COM0271AA

7

RAIL17COM0270AA

8

RAIL17COM0269AA

9

7. Install the heating hose to the engine.

8. Install the heating hose to the engine.

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Engine - Engine and crankcase

9. Install the heating hose to the hose clamp.

RAIL17COM0268AA

10

RAIL17COM0267AA

11

RAIL17COM0266AA

12

10. Connect the engine pre-heating wire.

11. Connect the fuel overflow hose.

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Engine - Engine and crankcase

12. Connect the starter cable.

RAIL17COM0265AA

13

RAIL17COM0264AA

14

RAIL17COM0263AA

15

13. Connect the engine controller connector.

14. Install the cooling hose (1).

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Engine - Engine and crankcase

15. Install the relay with bracket using hardware removed earlier.

RAIL17COM0262AA

16

RAIL17COM0261AA

17

RAIL17COM0259AA

18

16. Install the hoses (1) to the cooling pump. Connect the wiring to the alternator (2).

17. Connect the hose (1) to the hydraulic tank.

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Engine - Engine and crankcase

18. Install the drain hose to the oil tank.

RAIL17COM0272AA

19

RAIL17COM0246AA

20

RAIL17COM0252AA

21

RAIL17COM0242AA

22

19. Make sure the engine oil drain plug is secure.

20. Install the covers removed earlier.

21. Connect the batteries.

NOTE: First connect the terminal to the battery positive pole (red cable), then the terminal to the negative pole (black cable).

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Engine - Engine and crankcase

22. Install the rubber gasket.

RAIL17COM0281AA

23

RAIL17COM0282AA

24

RAIL17COM0258AA

25

23. Install cab mounts.

24. Connect the electrical connector to the compressor.

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Engine - Engine and crankcase

25. Connect the hoses to the filter dehydrator.

Install the hoses to the A/C compressor.

NOTE: Applicable only for machines with an air-conditioning system.

RAIL17COM0257AA

Next operation: Aftercooler - Install (10.310) Next operation: Hood - Install (90.100)

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26

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

14

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

3

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Engine - 10 Engine cooling system - 400

SV208D

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Contents Engine - 10 Engine cooling system - 400

SERVICE Radiator Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Engine - Engine cooling system

Radiator - Remove Prior operation: Hood - Remove (90.100) 1. Use the disconnect switch to disconnect the batteries.

RAIL17COM0249AA

1

RAIL17COM0300AA

2

RAIL17COM0246AA

3

2. Drain the hydraulic oil into a suitable container.

NOTE: The drained oil volume is 72 L (19 US gal).

3. Drain the engine coolant into a suitable container.

NOTE: The drained coolant volume is 28.0 L (7.4 US gal)

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Engine - Engine cooling system

4. Disconnect the sensor (1) and remove the hose (2) from the expansion tank.

RAIL17COM0288AA

4

RAIL17COM0242AA

5

RAIL17COM0251AA

6

RAIL17COM0294AA

7

5. Disconnect the batteries.

Remove the bracket with batteries and put aside.

NOTE: First disconnect the terminal from the battery negative pole (black cable), then the terminal from the positive pole (red cable).

6. Remove the cover.

7. Remove the elbow from the combined cooler.

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Engine - Engine cooling system

8. Remove the air suction hose.

RAIL17COM0291AA

8

RAIL17COM0240AA

9

9. Remove the screws (1) from the air filter bracket. Disconnect the connector (2).

10. Remove the screws (1). Put aside the bracket with the air filter.

RAIL17COM0241AA

10

RAIL17COM0292AA

11

11. Remove the hoses (1) from the cooling hydraulic motor, cover the outlets. Disconnect the connector (2).

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Engine - Engine cooling system

12. Remove the hoses from the combined cooler.

RAIL17COM0293AA

12

RAIL17COM0297AA

13

RAIL17COM0298AA

14

13. Remove bolts (1) from the cooler holders on either side.

14. Remove the cooler mounting bolts (1).

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Engine - Engine cooling system

15. Using appropriate lifting equipment, lift the cooler and set aside.

RAIL17COM0299AA

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15

Engine - Engine cooling system

Radiator - Install 1. Slowly lower the cooler into place and install the mounting bolts (1).

RAIL17COM0298AA

1

RAIL17COM0297AA

2

RAIL17COM0293AA

3

2. Install bolts (1) for the cooler holders on either side.

3. Install the hoses to the combined cooler.

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Engine - Engine cooling system

4. Install the hoses (1) to the cooling hydraulic motor.

Connect the connector (2).

RAIL17COM0292AA

4

RAIL17COM0241AA

5

RAIL17COM0240AA

6

RAIL17COM0291AA

7

5. Install the air cleaner with the bracket and secure with the hardware (1) removed earlier.

6. Install the screws (1) to the air cleaner bracket. Connect the electrical connector (2).

7. Install the air suction hose.

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Engine - Engine cooling system

8. Install the elbow to the combined cooler.

RAIL17COM0294AA

8

RAIL17COM0251AA

9

9. Install the cover.

10. Connect the batteries.

NOTE: First connect the terminal to the battery positive pole (red cable), then the terminal to the negative pole (black cable).

RAIL17COM0242AA

10

RAIL17COM0288AA

11

11. Connect the sensor (1) and install the hose (2) to the expansion tank.

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Engine - Engine cooling system

12. Make sure the coolant drain valve is closed.

Fill the cooing system with the recommended amount.

NOTE: The coolant volume is 28.0 L (7.4 US gal)

RAIL17COM0246AA

12

RAIL17COM0300AA

13

RAIL17COM0249AA

14

13. Make sure the oil tank valve is closed and fill to the recommended level.

NOTE: The oil volume is 72 L (19 US gal).

14. Use the disconnect switch to connect the batteries.

Next operation: Hood - Install (90.100)

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Index Engine - 10 Engine cooling system - 400 Radiator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

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

3

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Engine - 10 Aftercooler - 310

SV208D

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Contents Engine - 10 Aftercooler - 310

SERVICE Aftercooler Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Engine - Aftercooler

Aftercooler - Remove Prior operation: Hood - Remove (90.100) 1. Use the dis connector to disconnect the battery.

RAIL17COM0249AA

1

RAIL17COM0247AA

2

RAIL17COM0232AA

3

RAIL17COM0233AA

4

2. Drain the engine coolant into a suitable container.

3. Remove the hose (1).

4. Run the hose through the bushing.

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Engine - Aftercooler

5. Remove the engine cooling hose.

RAIL17COM0234AA

5

RAIL17COM0235AA

6

RAIL17COM0236AA

7

RAIL17COM0237AA

8

6. Remove the air suction hoses (1) and (2).

7. Remove the hose and disconnect the connector from the filter dehydrator.

NOTE: Applicable only for machines with an air-conditioning system.

8. Remove the hose from the evaporator.

NOTE: Applicable only for machines with an air-conditioning system.

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Engine - Aftercooler

9. Remove hoses (1) and (2) from fuel filter. Disconnect sensor (3).

RAIL17COM0253AA

9

10. Remove the exhaust frame.

RAIL17COM0238AA

10

RAIL17COM0248AA

11

RAIL17COM0239AA

12

11. Disconnect the elbow (1) from the exhaust piping (2).

12. Hang the frame with the exhaust on the crane and put aside.

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Engine - Aftercooler

13. Remove the screws (1) from the air filter bracket. Disconnect the connector (2).

RAIL17COM0240AA

13

RAIL17COM0241AA

14

RAIL17COM0242AA

15

RAIL17COM0254AA

16

14. Remove the screws (1). Put aside the bracket with the air filter.

15. Disconnect the batteries.

Remove the bracket with batteries and put aside.

NOTE: First disconnect the terminal from the battery negative pole (black cable), then the terminal from the positive pole (red cable).

16. Remove the pipe from the cooler.

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Engine - Aftercooler

17. Remove the fan covers.

RAIL17COM0243AA

17

RAIL17COM0251AA

18

RAIL17COM0244AA

19

RAIL17COM0255AA

20

18. Remove the cover.

19. Remove the nuts (1) from the after cooler mounts.

20. Remove the mounting bolts (1) from both sides of the cooler.

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Engine - Aftercooler

21. Using appropriate lifting equipment, pull cooler out and set aside.

RAIL17COM0245AA

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21

Engine - Aftercooler

Aftercooler - Install 1. Lower the cooler into place.

RAIL17COM0245AA

1

RAIL17COM0255AA

2

RAIL17COM0244AA

3

RAIL17COM0251AA

4

2. Install the mounting bolts (1), on both sides removed earlier.

3. Install the nuts (1) on the bottom of the cooler.

4. Install the cover using the hardware removed earlier.

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Engine - Aftercooler

5. Install the fan covers.

RAIL17COM0243AA

5

RAIL17COM0254AA

6

RAIL17COM0242AA

7

RAIL17COM0241AA

8

6. Install the pipe to the cooler.

7. Connect the batteries.

NOTE: First connect the terminal to the battery positive pole (red cable), then the terminal to the negative pole (black cable).

8. Install the air filter bracket and secure with the screws (1) removed earlier.

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Engine - Aftercooler

9. Install the air filter bracket mounting hardware (1) removed earlier. Connect the connector (2).

RAIL17COM0240AA

9

10. Lower the exhaust and mounting frame into place.

RAIL17COM0239AA

10

RAIL17COM0248AA

11

RAIL17COM0238AA

12

11. Connect the elbow (1) to the exhaust piping (2).

12. Install the exhaust frame.

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13. Install hoses (1) and (2) to the fuel filter. Connect sensor (3).

RAIL17COM0253AA

13

RAIL17COM0237AA

14

RAIL17COM0236AA

15

RAIL17COM0250AA

16

14. Install the hose to the evaporator.

NOTE: Applicable only for machines with an air-conditioning system.

15. Install the hose and connect the connector to the filter dehydrator.

NOTE: Applicable only for machines with an air-conditioning system.

16. Recharge the A/C system if required.

NOTE: Applicable only for machines with an air-conditioning system.

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Engine - Aftercooler

17. Install the air suction hoses (1) and (2).

RAIL17COM0235AA

17

RAIL17COM0234AA

18

RAIL17COM0233AA

19

RAIL17COM0232AA

20

18. Install the engine cooling hose.

19. Run the hose through the bushing.

20. Install the hose (1).

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Engine - Aftercooler

21. Fill the coolant to the recommended level. Make sure the coolant drain valve is closed.

RAIL17COM0247AA

21

RAIL17COM0249AA

22

22. Use the dis connector to connect the battery.

Next operation: Hood - Install (90.100)

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Index Engine - 10 Aftercooler - 310 Aftercooler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Aftercooler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

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

SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 2018 CNH Industrial America LLC. All rights reserved.

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

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

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

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

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

48150518 26/02/2018 EN

SERVICE MANUAL Hydrostatic drive SV208D

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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

SV208D

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Contents Hydrostatic drive - 29 Pump and motor components - 218

SERVICE Hydrostatic circuit supply pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Motor Remove - Drum travel hydraulic motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install - Drum travel hydraulic motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Remove - Rear wheel hydraulic travel motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Install - Rear wheel hydraulic travel motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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Hydrostatic drive - Pump and motor components

Hydrostatic circuit supply pump - Remove Prior operation: Hood - Remove (90.100) 1. Remove nuts from rubber-metals of the cab.

RAIL17COM0374AA

1

RAIL17COM0375AA

2

RAIL17COM0375AA

3

2. Take off the cover of the cab lifting switch. Lift the cab using the switch.

3. Turn off the battery using the disconnect switch.

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Hydrostatic drive - Pump and motor components

4. Remove the bolts. Set the rubber partition aside.

RAIL17COM0373AA

4

RAIL17COM0377AA

5

RAIL17COM0370AA

6

5. Use a suitable container for capturing any leaking fluids under the pumps. Remove hoses from hydraulic pumps. Plug and cap hydraulic hoses and fittings.

6. Disconnect wiring from the pumps.

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Hydrostatic drive - Pump and motor components

7. Suspend vibration hydraulic pump with a suitable lifting device, remove bolts connecting both hydraulic pumps.

Slide out and set aside.

RAIL17COM0378AA

7

RAIL17COM0376AA

8

RAIL17COM0379AA

9

8. Suspend hydrostatic drive pump on a suitable lifting device. Remove bolts (1) off flange.

9. Put aside the pump with the flange. Remove the bolts (1) to remove the flange.

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Hydrostatic drive - Pump and motor components

Hydrostatic circuit supply pump - Install 1. Connect the hydrostatic drive pump to the flange using bolts (1) removed earlier.

RAIL17COM0379AA

1

RAIL17COM0376AA

2

RAIL17COM0378AA

3

2. Slide the assembly into the clutch. Install the bolts (1) into the flange.

3. Mount the vibration pump.

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Hydrostatic drive - Pump and motor components

4. Install the hoses on the pump.

RAIL17COM0377AA

4

RAIL17COM0370AA

5

RAIL17COM0373AA

6

5. Connect the wiring to the pump.

6. Install the rubber partition.

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Hydrostatic drive - Pump and motor components

7. Install the nuts for rubber-metals of the cab.

RAIL17COM0374AA

Next operation: Hood - Install (90.100)

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7

Hydrostatic drive - Pump and motor components

Motor - Remove - Drum travel hydraulic motor 1. Place a suitable container underneath the travel hydraulic motor.

RAIL17COM0380AA

1

RAIL17COM0385AA

2

2. Remove the hydraulic motor cover.

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Hydrostatic drive - Pump and motor components

3. Remove the travel hydraulic motor hoses.

Plug the outlets of hoses and the hydraulic motor.

RAIL17COM0381AA

3

RAIL17COM0382AA

4

RAIL17COM0384AA

5

4. Disconnect the wires from the travel hydraulic motor.

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Hydrostatic drive - Pump and motor components

5. Tie the hoses to the mirror on the cab. Suspend the hydraulic motor with a suitable lifting device. remove the motor mounting bolts (1). Remove the motor and set it aside.

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RAIL17COM0383AA

6

RAIL17COM0384AA

7

Hydrostatic drive - Pump and motor components

Motor - Install - Drum travel hydraulic motor 1. Install the four bolts (1) for the vibration hydraulic motor.

RAIL17COM0384AA

1

RAIL17COM0384AA

2

RAIL17COM0381AA

3

2. Connect the wires to the travel hydraulic motor.

3. Install the travel hydraulic motor hoses.

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Hydrostatic drive - Pump and motor components

4. Install the hydraulic motor cover.

RAIL17COM0385AA

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4

Hydrostatic drive - Pump and motor components

Motor - Remove - Rear wheel hydraulic travel motor NOTE: The following instruction applies to both rear wheel travel motors.

1. Using appropriate lifting equipment, raise and support the side to be serviced. Remove the bolts (1) securing the wheel.

RAIL17COM0386AA

1

RAIL17COM0391AA

2

RAIL17COM0387AA

3

2. Using appropriate lifting device. remove the wheel.

3. Remove the guard.

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Hydrostatic drive - Pump and motor components

4. Disconnect the wiring from the hydraulic motor.

RAIL17COM0389AA

4

RAIL17COM0390AA

5

RAIL17COM0390AA

6

5. Use a suitable container to catch any hydraulic oil. Remove the hydraulic lines from the motor, cap and plug the lines and open ports.

6. Remove the motor mounting bolts (1), remove the motor.

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Hydrostatic drive - Pump and motor components

Motor - Install - Rear wheel hydraulic travel motor NOTE: The following instruction applies to both rear wheel travel motors.

1. Install the motor and secure with the bolts (1) removed earlier.

RAIL17COM0390AA

1

RAIL17COM0390AA

2

RAIL17COM0389AA

3

2. Connect the hydraulic lines (1).

3. Connect the wiring to the hydraulic motor.

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Hydrostatic drive - Pump and motor components

4. Install the guard.

RAIL17COM0387AA

4

RAIL17COM0391AA

5

RAIL17COM0386AA

6

5. Install the wheel and secure with the bolts (1) removed earlier.

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Index Hydrostatic drive - 29 Pump and motor components - 218 Hydrostatic circuit supply pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Hydrostatic circuit supply pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Motor - Install - Drum travel hydraulic motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

Motor - Install - Rear wheel hydraulic travel motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

Motor - Remove - Drum travel hydraulic motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Motor - Remove - Rear wheel hydraulic travel motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

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Hydrostatic drive - 29 Hydrostatic transmission - 202

SV208D

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Contents Hydrostatic drive - 29 Hydrostatic transmission - 202

FUNCTIONAL DATA Hydrostatic transmission Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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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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Index Hydrostatic drive - 29 Hydrostatic transmission - 202 Hydrostatic transmission - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3

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

SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 2018 CNH Industrial America LLC. All rights reserved.

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

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

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

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

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

48150518 26/02/2018 EN

SERVICE MANUAL Hydraulic systems SV208D

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35

Contents Hydraulic systems - 35

[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.106] Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.995] Compaction/vibration hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4

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Hydraulic systems - 35 Hydraulic systems - 000

SV208D

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Contents Hydraulic systems - 35 Hydraulic systems - 000

FUNCTIONAL DATA Hydraulic systems Hydraulic schema - Wheel differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic schema - Interaxle differential lock ATC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Hydraulic schema - Electro-hydraulic cab and hood lift and lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic schema - Wheel differential lock Item 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.

26.

27.

28.

29.

Description Travel hydraulic pump Vibration hydraulic pump Steering hydraulic pump Cooling hydraulic pump N/A Drum travel hydraulic motor RH wheel travel hydraulic motor LH wheel travel hydraulic motor Vibration hydraulic motor Cooling hydraulic motor N/A Steering hydraulic cylinder Power-assisted steering N/A Brake block Flushing block Divider block N/A Filter One-way valve Filler neck Level indicator Combined cooler N/A Temperature sensor Temperature sensor Quick-coupler for filling Quick-coupler for measuring Quick-coupler for measuring

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Hydraulic systems - Hydraulic systems

RAIL18COM0004JA

1

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic schema - Interaxle differential lock ATC Item 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.

26.

27.

28.

29.

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Description Travel hydraulic pump Vibration hydraulic pump Steering hydraulic pump Cooling hydraulic pump N/A Drum travel hydraulic motor RH wheel travel hydraulic motor LH wheel travel hydraulic motor Vibration hydraulic motor Cooling hydraulic motor N/A Steering hydraulic cylinder Power-assisted steering N/A Brake block RTM control block RTM module N/A Filter One-way valve Filler neck Level indicator Combined cooler N/A Temperature sensor Temperature sensor Quick-coupler for filling Quick-coupler for measuring Quick-coupler for measuring

Hydraulic systems - Hydraulic systems

RAIL18COM0005JA

1

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Hydraulic systems - Hydraulic schema - Electro-hydraulic cab and hood lift and lower Item 1.

2.

3.

4.

5.

6.

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Description Hydraulic tank Lift/lower unit Lift/lower block Cab lift/lower hydraulic cylinder Hood lift/lower hydraulic cylinder Hydraulic lock

Hydraulic systems - Hydraulic systems

RAIL18COM0006JA

1

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Index Hydraulic systems - 35 Hydraulic systems - 000 Hydraulic systems - Hydraulic schema - Interaxle differential lock ATC . . . . . . . . . . . . . . . . . . . . . . . .

6

Hydraulic systems - Hydraulic schema - Electro-hydraulic cab and hood lift and lower . . . . . . . . . . .

8

Hydraulic systems - Hydraulic schema - Wheel differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

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Hydraulic systems - 35 Variable displacement pump - 106

SV208D

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Contents Hydraulic systems - 35 Variable displacement pump - 106

SERVICE Pump Remove - Compaction/vibration pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install - - Compaction/vibration pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Pump - Remove - Compaction/vibration pump Prior operation: Hood - Remove (90.100) 1. Remove nuts from rubber-metals of the cab.

RAIL17COM0374AA

1

RAIL17COM0375AA

2

RAIL17COM0375AA

3

2. Take off the cover of the cab lifting switch. Lift the cab using the switch.

3. Turn off the battery using the disconnect switch.

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4. Remove the bolts. Set the rubber partition aside.

RAIL17COM0373AA

4

RAIL17COM0377AA

5

RAIL17COM0370AA

6

5. Use a suitable container for capturing any leaking fluids under the pumps. Remove hoses from hydraulic pumps. Plug and cap hydraulic hoses and fittings.

6. Disconnect wiring from the pumps.

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7. Remove the steering pump.

RAIL17COM0316AA

7

RAIL17COM0378AA

8

8. Suspend vibration hydraulic pump with a suitable lifting device, remove bolts connecting both hydraulic pumps.

Slide out and set aside.

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Pump - Install - - Compaction/vibration pump 1. Mount the vibration pump.

RAIL17COM0378AA

1

RAIL17COM0316AA

2

RAIL17COM0377AA

3

2. Install the steering pump.

3. Install the hoses on the pump.

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4. Connect the wiring to the pump.

RAIL17COM0370AA

4

RAIL17COM0373AA

5

RAIL17COM0374AA

6

5. Install the rubber partition.

6. Install the nuts for rubber-metals of the cab.

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Index Hydraulic systems - 35 Variable displacement pump - 106 Pump - Install - - Compaction/vibration pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Pump - Remove - Compaction/vibration pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

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

SV208D

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

SERVICE Oil cooler/Heat exchanger Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Oil cooler/Heat exchanger - Remove Prior operation: Hood - Remove (90.100) 1. Use the disconnect switch to disconnect the batteries.

RAIL17COM0249AA

1

RAIL17COM0300AA

2

RAIL17COM0246AA

3

2. Drain the hydraulic oil into a suitable container.

NOTE: The drained oil volume is 72 L (19 US gal).

3. Drain the engine coolant into a suitable container.

NOTE: The drained coolant volume is 28.0 L (7.4 US gal)

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4. Disconnect the sensor (1) and remove the hose (2) from the expansion tank.

RAIL17COM0288AA

4

RAIL17COM0242AA

5

RAIL17COM0251AA

6

RAIL17COM0294AA

7

5. Disconnect the batteries.

Remove the bracket with batteries and put aside.

NOTE: First disconnect the terminal from the battery negative pole (black cable), then the terminal from the positive pole (red cable).

6. Remove the cover.

7. Remove the elbow from the combined cooler.

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8. Remove the air suction hose.

RAIL17COM0291AA

8

RAIL17COM0240AA

9

9. Remove the screws (1) from the air filter bracket. Disconnect the connector (2).

10. Remove the screws (1). Put aside the bracket with the air filter.

RAIL17COM0241AA

10

RAIL17COM0292AA

11

11. Remove the hoses (1) from the cooling hydraulic motor, cover the outlets. Disconnect the connector (2).

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12. Remove the hoses from the combined cooler.

RAIL17COM0293AA

12

RAIL17COM0297AA

13

RAIL17COM0298AA

14

13. Remove bolts (1) from the cooler holders on either side.

14. Remove the cooler mounting bolts (1).

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15. Using appropriate lifting equipment, lift the cooler and set aside.

RAIL17COM0299AA

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15

Hydraulic systems - Reservoir, cooler, and filters

Oil cooler/Heat exchanger - Install 1. Slowly lower the cooler into place and install the mounting bolts (1).

RAIL17COM0298AA

1

RAIL17COM0297AA

2

RAIL17COM0293AA

3

2. Install bolts (1) for the cooler holders on either side.

3. Install the hoses to the combined cooler.

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4. Install the hoses (1) to the cooling hydraulic motor.

Connect the connector (2).

RAIL17COM0292AA

4

RAIL17COM0241AA

5

RAIL17COM0240AA

6

RAIL17COM0291AA

7

5. Install the air cleaner with the bracket and secure with the hardware (1) removed earlier.

6. Install the screws (1) to the air cleaner bracket. Connect the electrical connector (2).

7. Install the air suction hose.

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8. Install the elbow to the combined cooler.

RAIL17COM0294AA

8

RAIL17COM0251AA

9

9. Install the cover.

10. Connect the batteries.

NOTE: First connect the terminal to the battery positive pole (red cable), then the terminal to the negative pole (black cable).

RAIL17COM0242AA

10

RAIL17COM0288AA

11

11. Connect the sensor (1) and install the hose (2) to the expansion tank.

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12. Make sure the coolant drain valve is closed.

Fill the cooing system with the recommended amount.

NOTE: The coolant volume is 28.0 L (7.4 US gal)

RAIL17COM0246AA

12

RAIL17COM0300AA

13

RAIL17COM0249AA

14

13. Make sure the oil tank valve is closed and fill to the recommended level.

NOTE: The oil volume is 72 L (19 US gal).

14. Use the disconnect switch to connect the batteries.

Next operation: Hood - Install (90.100)

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

8

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

3

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Hydraulic systems - 35 Compaction/vibration hydraulic system - 995

SV208D

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

FUNCTIONAL DATA Compaction/vibration hydraulic system Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Compaction/vibration motor Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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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 rotation of the vibration shaft, the two eccentric weights (1) are locked together which creates an extreme vibration by spinning one large mass of weight in one direction. During the low amplitude rotation of the vibration shaft, the shaft is spun in the opposite direction. Spinning the shaft in the opposite direction disengages the locked weights (2) 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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4

Hydraulic systems - Compaction/vibration hydraulic system

Compaction/vibration motor - Remove 1. Using a suitable container to catch any hydraulic oil.

RAIL17COM0453AA

1

RAIL17COM0452AA

2

2. Remove hoses (1) from the hydraulic motor, cap and plug the hose ends and outlets of the motor. Remove the hydraulic motor, set it aside.

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Compaction/vibration motor - Install 1. Install motor, secure with the bolts removed earlier.

Connect the hydraulic lines (1).

RAIL17COM0452AA

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1

Index Hydraulic systems - 35 Compaction/vibration hydraulic system - 995 Compaction/vibration hydraulic system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Compaction/vibration motor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Compaction/vibration motor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

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

SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 2018 CNH Industrial America LLC. All rights reserved.

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

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

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

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

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

48150518 26/02/2018 EN

SERVICE MANUAL Frames and ballasting SV208D

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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

SV208D

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Contents Frames and ballasting - 39 Frame - 100

SERVICE Articulation frame pivot Remove - Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install - Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Frames and ballasting - Frame

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

RAIL17COM0328AA

1

RAIL17COM0329AA

2

RAIL17COM0345AA

3

2. Remove the packaging piece (1)

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Frames and ballasting - Frame

3. Using a suitable device, press the pins (1) out of the ends of the piston of the cylinder (2).

RAIL17COM0346AA

4

RAIL17COM0347AA

5

RAIL17COM0330AA

6

4. Remove the hose clamps on the drum frame.

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

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Frames and ballasting - Frame

6. Remove the hydraulic motor.

RAIL17COM0332AA

7

RAIL17COM0333AA

8

RAIL17COM0334AA

9

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

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

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Frames and ballasting - Frame

9. Remove the bolts (1).

RAIL17COM0348AA

10

RAIL17COM0335AA

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 (1).

RAIL17COM0336AA

13

RAIL17COM0337AA

14

RAIL17COM0338AA

15

14. Move the plate aside.

15. Remove the bolts.

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Frames and ballasting - Frame

16. Suspend the hub assembly with adequate lifting equipment (1).

17. Set the bearing aside.

RAIL17COM0339AA

16

RAIL17COM0340AA

17

RAIL17COM0341AA

18

18. Remove the nut.

19. Remove the clamps of the pin.

20. Press the pins (1) out, using a jack.

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Frames and ballasting - Frame

21. Using adequate lifting equipment, set the hub assembly aside.

RAIL17COM0342AA

19

RAIL17COM0343AA

20

RAIL17COM0344AA

21

22. Remove the covers (1) and the spacing pads (2).

23. Remove the bearings from the hub using a press.

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Frames and ballasting - Frame

Articulation frame pivot - Install - Bearings Prior operation: Order new bolts for the frame plate and the bearing on the frame plate.

1. Press the bearings into the mount.

RAIL17COM0344AA

1

RAIL17COM0343AA

2

RAIL17COM0342AA

3

2. Install the covers (1) and the spacing pads (2).

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 (1), using a jack.

5. Install the clamps of the pin.

RAIL17COM0341AA

4

RAIL17COM0340AA

5

RAIL17COM0339AA

6

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.

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Frames and ballasting - Frame

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

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

SS13F301

7

RAIL17COM0336AA

8

SS13F337

9

10. Carefully place the frame plate in position.

11. Apply LOCTITE® 243™ to the bolts (1).

NOTE: Install new bolts.

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

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

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

RAIL17COM0335AA

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10

Frames and ballasting - Frame

14. Install the bolts (1).

RAIL17COM0348AA

11

RAIL17COM0332AA

12

RAIL17COM0330AA

13

15. Install the hydraulic motor.

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

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Frames and ballasting - Frame

17. Install the hose clamps on the drum frame.

SS13F152

14

RAIL17COM0346AA

15

RAIL17COM0345AA

16

18. Press the pins (1) into the ends of the piston of the cylinder (2).

19. Install the packaging piece (1)

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Index Frames and ballasting - 39 Frame - 100 Articulation frame pivot - Install - Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

Articulation frame pivot - Remove - Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

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Frames and ballasting - 39 Vibratory roller - 500

SV208D

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Contents Frames and ballasting - 39 Vibratory roller - 500

SERVICE Vibratory roller Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Vibratory drum mounts Remove - Left side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install - Left side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Disassemble - Left side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Assemble - Left side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Remove - Right side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Install - Right side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Remove - Vibrator system weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Install - Vibrator system weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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Frames and ballasting - Vibratory roller

Vibratory roller - Remove 1. Lift the drum frame until the drum just touches the ground. Support on both sides firmly with fixture.

RAIL17COM0392AA

1

RAIL17COM0393AA

2

RAIL17COM0394AA

3

2. Remove holders of vibration hydraulic motor hoses.

3. Remove the vibration hydraulic motor and put on the frame side.

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Frames and ballasting - Vibratory roller

4. Remove holders of hoses of the travel hydraulic motor.

RAIL17COM0395AA

4

RAIL17COM0380AA

5

RAIL17COM0381AA

6

5. Place a suitable container underneath the travel hydraulic motor.

6. Remove the hoses of the travel hydraulic motor.

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7. Plug up outlets of hoses and the hydraulic motor.

RAIL17COM0382AA

7

RAIL17COM0383AA

8

RAIL17COM0397AA

9

8. Tie up hoses to the mirror on the cab.

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

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10. Unscrew plug in front cross beam, install hooks.

RAIL17COM0396AA

10

RAIL17COM0399AA

11

RAIL17COM0400AA

12

11. Remove bolts (1) on both sides, set crossbeam aside.

12. Loosen connecting bolts (1) of the frame with the bracket on the left side and on the right side.

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13. Slide the rubber mounting off.Tighten rubber mounting by 8.0 – 10.0 mm (0.3 – 0.4 in)

RAIL17COM0401AA

13

RAIL17COM0402AA

14

RAIL17COM0403AA

15

14. After having removed bolts that connect the frame of the drum, remove spacers.

15. Roll the drum from the frame.

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16. Unscrew drain plug from the lid of the vibrator, drain oil into a suitable container.

RAIL17COM0404AA

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16

Frames and ballasting - Vibratory roller

Vibratory roller - Install 1. Install drain plug in the left lid in lower position.

RAIL17COM0404AA

1

RAIL17COM0403AA

2

RAIL17COM0402AA

3

2. Roll the drum into the frame.

3. Install the spacers.

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4. Slide the rubber mounting on. Torque the rubber mounting to 8.0 – 10.0 mm (0.3 – 0.4 in).

RAIL17COM0401AA

4

RAIL17COM0400AA

5

RAIL17COM0399AA

6

5. Install the connecting bolts of the frame with the bracket on the left side and (1) on the right side.

6. Install the cross member.

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

RAIL17COM0397AA

7

RAIL17COM0381AA

8

RAIL17COM0395AA

9

8. Install the travel hydraulic motor hoses.

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

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

RAIL17COM0394AA

10

RAIL17COM0393AA

11

11. Install holders for vibration hydraulic motor hoses.

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Frames and ballasting - Vibratory roller

Vibratory drum mounts - Remove - Left side 1. Use proper chock to prevent movement.

RAIL17COM0405AA

1

RAIL17COM0406AA

2

RAIL17COM0407AA

3

2. Turn bracket (1) and remove bolts (2) one after the other. Remove the other two screws in the horizontal axis after the bracket is hinged on the crane.

3. Hang the bracket on a suitable lifting device.

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4. Remove last two bolts (1).

RAIL17COM0406AA

4

RAIL17COM0409AA

5

RAIL17COM0410AA

6

5. Remove console together with the vibrator plate from the drum, set aside.

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Frames and ballasting - Vibratory roller

Vibratory drum mounts - Install - Left side 1. Install console together with the vibrator plate to the drum.

RAIL17COM0410AA

1

RAIL17COM0406AA

2

RAIL17COM0409AA

3

2. Install the bolts bolts (1).

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3. Turn bracket (1) and install bolts (2) one after the other.

RAIL17COM0406AA

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4

Frames and ballasting - Vibratory roller

Vibratory drum mounts - Disassemble - Left side 1. Remove bolts (1), remove console (2) from rubberized metal pieces.

RAIL17COM0411AA

1

RAIL17COM0412AA

2

RAIL17COM0413AA

3

2. Vibrator plate to be rotated and placed on the rubber mounting.

3. Bend the tab of the lock washer to disengage the nut.

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4. Remove nut (1) and lock washer (2).

RAIL17COM0414AA

4

RAIL17COM0416AA

5

RAIL17COM0417AA

6

5. Turn vibrator plate, with the hub upside down and support.

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6. Remove bolts. Pull off the hub from the bracket.

RAIL17COM0418AA

7

RAIL17COM0419AA

8

7. Remove the bearing (1) press out bearing cups (2).

Remove the seal ring (3) and collar (4).

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Frames and ballasting - Vibratory roller

Vibratory drum mounts - Assemble - Left side 1. Press in bearing cups (1)Install the collar (2)and the seal ring (3)

RAIL17COM0419AA

1

RAIL17COM0421AA

2

RAIL17COM0422AA

3

2. Heat the ring (1) to 90.0 °C (194.0 °F) if replacing. Install onto the vibrator plate. Install the O-ring (2). Heat the bearing (3) to 90.0 °C (194.0 °F) and install onto the vibrator plate.

3. Fill the bearings with grease and install the hub.

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4. Heat the bearing to 90.0 °C (194.0 °F) and install into the hub.

RAIL17COM0423AA

4

RAIL17COM0416AA

5

RAIL17COM0415AA

6

5. Install the nut (1) and lock washer (2).

6. Tighten the nut until a rolling torque of 70.0 – 80.0 N·m (51.6 – 59.0 lb ft) is achieved on the hub.

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Frames and ballasting - Vibratory roller

Vibratory drum mounts - Remove - Right side 1. Turn the drum to position in the image.

RAIL17COM0424AA

1

RAIL17COM0425AA

2

RAIL17COM0435AA

3

2. Hang the bracket on suitable lifting device.

3. Remove bolts (1) connecting carrier (2) with rubber mountings.

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Frames and ballasting - Vibratory roller

4. Set the console with the driving lug aside.

RAIL17COM0426AA

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4

Frames and ballasting - Vibratory roller

Vibratory drum mounts - Install - Right side 1. Install the console with the driving lug into place on the drum.

RAIL17COM0426AA

1

RAIL17COM0435AA

2

2. Install the bolts (1) connecting carrier (2) with rubber mountings.

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Frames and ballasting - Vibratory roller

Vibratory drum mounts - Remove - Vibrator system weights 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: 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.

RAIL17COM0427AA

1

RAIL17COM0428AA

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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Frames and ballasting - Vibratory roller

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).

RAIL17COM0429AA

3

RAIL17COM0430AA

4

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

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Vibratory drum mounts - Install - Vibrator system weights 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. For installing the outer rings of the bearings (19) to the covers (7) and (8), follow pairing with internal bearing rings.

RAIL17COM0431AA

1

RAIL17COM0432AA

2

RAIL17COM0433AA

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).

RAIL17COM0434AA

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4

Index Frames and ballasting - 39 Vibratory roller - 500 Vibratory drum mounts - Assemble - Left side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

Vibratory drum mounts - Disassemble - Left side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

Vibratory drum mounts - Install - Left side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

Vibratory drum mounts - Install - Right side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

Vibratory drum mounts - Install - Vibrator system weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

Vibratory drum mounts - Remove - Left side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

Vibratory drum mounts - Remove - Right side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

Vibratory drum mounts - Remove - Vibrator system weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

Vibratory roller - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Vibratory roller - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

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

SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 2018 CNH Industrial America LLC. All rights reserved.

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

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

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

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

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

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SERVICE MANUAL Steering SV208D

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41

Contents Steering - 41

[41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1 [41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 [41.206] Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3 [41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.4

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Steering - 41 Steering control - 101

SV208D

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Contents Steering - 41 Steering control - 101

SERVICE Manual steering wheel Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Steering - Steering control

Manual steering wheel - Remove 1. Remove the steering-column shaft along with the steering wheel.

RAIL17COM0474AA

1

RAIL17COM0468AA

2

2. Pull out the shaft. Shaft end has dust cover put on.

NOTE: Unless you pull out the shaft complete with the dust cover (remains fitted on servosteering shaft), take it out.

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Steering - Steering control

Manual steering wheel - Install 1. Reassemble the steering wheel. Before you reassemble, put the dust cover on shaft end.

RAIL17COM0472AA

1

RAIL17COM0473AA

2

2. Position the steering wheel so its handle is for left hand (the drum must be turned for straight-ahead driving).

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Index Steering - 41 Steering control - 101 Manual steering wheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Manual steering wheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

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Steering - 41 Hydraulic control components - 200

SV208D

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Contents Steering - 41 Hydraulic control components - 200

SERVICE Steering valve Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Steering - Hydraulic control components

Steering valve - Remove 1. Use a suitable container to capture hydraulic oil. Mark the hydraulic hoses (1) and disconnect. Remove the steering unit.

NOTE: When reassembling, observe the correct hose connections according to the marking.

RAIL17COM0303AA

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1

Steering - Hydraulic control components

Steering valve - Install 1. Install the steering unit and secure with the bolts removed earlier. Connect the hydraulic hoses according the marking on removal.

RAIL17COM0303AA

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1

Index Steering - 41 Hydraulic control components - 200 Steering valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Steering valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

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Steering - 41 Pump - 206

SV208D

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Contents Steering - 41 Pump - 206

SERVICE Power steering pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Steering - Pump

Power steering pump - Remove 1. Remove the suction hose from the hydraulic tank.

RAIL17COM0314AA

1

RAIL17COM0315AA

2

RAIL17COM0316AA

3

2. Use a suitable container for capturing any leaking fluids under the pump. Remove the hoses from the steering pump. Plug the hose ends and outlets of the pump.

3. Remove the two mounting bolts (1). Remove the steering pump.

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Steering - Pump

Power steering pump - Install 1. Install the pump and secure with the bolts (1) removed earlier.

RAIL17COM0316AA

1

RAIL17COM0315AA

2

RAIL17COM0314AA

3

2. Connect the hoses removed earlier.

3. Connect the suction hose to the hydraulic tank.

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Index Steering - 41 Pump - 206 Power steering pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Power steering pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

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Steering - 41 Cylinders - 216

SV208D

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Contents Steering - 41 Cylinders - 216

SERVICE Articulation steering cylinder Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Steering - Cylinders

Articulation steering cylinder - Remove 1. Set the machine on a horizontal solid surface. Remove the covers (1).

RAIL17COM0296AA

1

RAIL17COM0318AA

2

RAIL17COM0319AA

3

2. To provide better access, set the steering in the max. steering wheel lock. Use a suitable container for capturing any leaking fluids under the cylinder.. Disconnect the hoses, cap and plug the hydraulic fittings and hoses.

3. Remove the plate (1) and press out the pin (2). Remove the hydraulic cylinder from the machine.

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Steering - Cylinders

Articulation steering cylinder - Install 1. Install the cylinder. Install the pin (1) and secure with the plate (2) removed earlier.

RAIL17COM0319AA

1

RAIL17COM0318AA

2

RAIL17COM0296AA

3

2. Connect the hoses to the cylinder.

3. Install the covers (1).

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Steering - Cylinders

Articulation steering cylinder - Disassemble 1. Lift and securely place the cylinder on a workbench.

Drain hydraulic oil from the cylinder. Unlock the cylinder gland.

NOTE: Be sure that the cylinder is placed horizontally.

RAIL17COM0320AA

1

RAIL17COM0321AA

2

RAIL17COM0325AA

3

RAIL17COM0326AA

4

2. Remove the gland nut using the appropriate size spanner wrench.

NOTE: If necessary gently heat the gland carrier to soften the thread sealant applied during manufacture.

3. Remove the gland nut along with the piston.

4. Remove the nut at the end of the piston. Reseal the piston and the gland nut.

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Steering - Cylinders

Articulation steering cylinder - Assemble 1. Coat the seals with petroleum jelly. Install the piston into the cylinder.

RAIL17COM0327AA

1

RAIL17COM0321AA

2

RAIL17COM0322AA

3

2. Install the gland nut and secure with an appropriate spanner wrench.

3. Lock the cylinder gland.

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Index Steering - 41 Cylinders - 216 Articulation steering cylinder - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Articulation steering cylinder - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Articulation steering cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Articulation steering cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

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

SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 2018 CNH Industrial America LLC. All rights reserved.

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

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

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

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

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

48150518 26/02/2018 EN

SERVICE MANUAL Cab climate control SV208D

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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

SV208D

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Contents Cab climate control - 50 Air conditioning - 200

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

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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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Index Cab climate control - 50 Air conditioning - 200 Air conditioning - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3

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

SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 2018 CNH Industrial America LLC. All rights reserved.

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

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

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

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

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

48150518 26/02/2018 EN

SERVICE MANUAL Electrical systems SV208D

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55

Contents Electrical systems - 55

[55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6

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Electrical systems - 55 Electrical system - 000

SV208D

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Contents Electrical systems - 55 Electrical system - 000

FUNCTIONAL DATA Electrical system Computer support tools - Component identification - Software and hardware (optional) . . . . . . . . . . . . . . 3 Computer support tools - Fault code index - Diagnosis troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Electrical systems - Electrical system

Electrical system Computer support tools - Component identification - Software and hardware (optional) NOTE: The BODAS system is only an option and not a requirement. Please call your technical support, if the BODAS system is desired.

Features The BODAS-service PC software tool provides a convenient and user-friendly method of executing service functions for BODAS controllers from Rexroth. Parameters could be displayed and edited, process variables displayed, and their values graphically plotted and recorded. In addition, error messages could be read out, reset as well as the application´s diagnostic configuration configured. Furthermore, functions are available for reading out and writing to the controller EEPROM. For BODAS controllers, equipped with CAN diagnosis, extensive version information on the controller is displayed.

For these controllers, in the event of an emergency, full access to all process variables and parameters is possible for a single service session via an "Emergency Access" (requires only the BODAS-service DEMO version).

BODAS-service also offers an option for the loading of application software, so-called HexFiles, onto BODAS controller RC and the transfer of display configuration Files onto the BODAS Display DI3.

The respective functions are enabled by a USB hardlock (license control).

BODAS-service contains BODEM 25 and FT2 (Not available from Windows 7).

The following license versions can be selected: • BODAS-service Diagnosis (contains BODEM25 license) • BODAS-service Flash Tool • BODAS-service Full Version (contains BODEM25 license) All of the listed functions can be executed on a PC or laptop.

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Electrical systems - Electrical system

Function/operating notes The BODAS-service PC software tool provides a convenient and user-friendly method of executing service functions for BODAS controllers from Rexroth. Depending on the license version which is purchased, the tool is characterized by the following functions: • Extremely user-friendly, through Windows user interface, free configurable work flow and online help • Simultaneous display of multiple parameters for modification settings • Simultaneous display of multiple process variables in graphical or numeric form • Printout of all settings and process variables for documentation purposes • Clear and easy-to-understand display of error messages • Easy-to-use data logger: Save measured values (process variables and parameters) to the hard disk • Selectable and expandable program language • Adjustable device language (relevant to controller data, up to 4 languages available) • Diagnosis Configuration for a BODAS or C application on BODAS controller RC • Transfer software from PC to a BODAS controller RC (flashing of application software) • Transfer of Display configuration Files onto BODAS Display DI3.

• Save the data contained in the EEPROM of a BODAS controller or transfer an EEPROM file (EPR file) to a BODAS controller • Command line control option for various BODAS functions, e-g flash programming or EPR file download Additional functions for BODAS controller RC beginning with CAN diagnosis: • Display of extensive version information • Emergency release of all parameters and process variables via an "Emergency Access" (beginning with the BODAS‑service DEMO version) for a one-time connection by means of the "Seed and Key" process NOTE: A Demo version of BODAS-service 3.x – capable of displaying data only – is available as a free download on the Internet at www.boschrexroth.com/mobile-electronics under the header "BODAS-Tools" or within the Rexroth media directory at the search criteria "Diagnosis Tool BODAS-service". The demo version does not allow to modify, save or delete any parameters or data.

Notebook All current models with CD-ROM and min. 2x USB connections should work.

Microsoft windows (XP, Vista or 7) is, however, required.

NOTE: For Windows 7, you may need to download the latest drivers from manufacturer websites.

SS12K423

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1

Electrical systems - Electrical system

Adapter cable CAN-to-USB adapter

SS12K424

2

SS12K425

3

SS12K426

4

CAN bus USB adapter Interface/port converter Install the enclosed driver before connecting the device.

NOTE: You will find the latest drivers at: www.peak-system.com /Products/CAN-interfaces/PCANUSB.

BODAS service software Install the enclosed driver before connecting the device.

NOTE: The enclosed USB dongle works with all versions of BODAS Service 3.x.

We recommend downloading the latest version: www.boschrexroth.com/Products/Mobile Hydraulics/Mobile Electronics/BODAS Tools.

NOTE: These instructions were written for BODAS version 3.3 Newer or older versions may differ in use.

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Electrical systems - Electrical system

Electrical system Computer support tools - Fault code index Diagnosis troubleshooting Fault description A message is displayed due to missing licence key.

Remedy 1. Connect the USB dongle from Bosch Rexroth to your computer.

2. Make sure that your computers USB ports are working.

SS12K439

1

1. Connect the CAN bus USB adapter to your computer.

No CAN-USB adapter found.

2. Make sure that your computers USB ports are working.

3. Make sure that Interface configuration was performed as described.

SS12K440

2

Search for BODAS controllers found nothing.

1. Connect the CAN bus USB adapter to the machine using the adapter cable.

2. Switch on the ignition on the machine.

3. Check the adapter cable connectors.

4. Make sure that BODAS Service settings were configured as described.

SS12K441

3

Although the BODAS controller is found, data transfer is 1. If not absolutely necessary, perform diagnosis while the diesel engine is stopped. incomplete or the connection is lost again after a short time.

2. Check the CAN bus USB adapter connectors for loose connections.

3. Reboot the notebook and switch the ignition off and back on the machine.

NOTE: If the multifunction unit displays a BUS error, there is probably a problem with the machine wiring.

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Index Electrical systems - 55 Electrical system - 000 Electrical system Computer support tools - Component identification - Software and hardware (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Electrical system Computer support tools - Fault code index - Diagnosis troubleshooting . . . . . . . .

6

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Electrical systems - 55 Harnesses and connectors - 100

SV208D

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Contents Electrical systems - 55 Harnesses and connectors - 100

FUNCTIONAL DATA Harnesses and connectors Overview - Best practice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Wiring harnesses Electrical schema - Electrical schema key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Electrical schema - Electrical schema - 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Electrical schema - Electrical schema - 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Electrical schema - Electrical schema - 03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Electrical schema - Cable harness number 1 - Main harness Part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Electrical schema - Cable harness number 1 - Main harness Part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Electrical schema - Cable harness number 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Electrical schema - Cable harness number 3 - Part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Electrical schema - Cable harness number 3 - Part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Electrical schema - Cable harness number 3 - Part 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Electrical schema - Cable harness number 4 - Armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Electrical schema - Cable harness number 5 - Wipers, washers, overhead light . . . . . . . . . . . . . . . . . . . 50 Electrical schema - Cab and hood harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Electrical schema - Wheel differential lock harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Electrical schema - Interaxle differential lock ATC harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Electrical schema - Front headlights harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Electrical schema - Rear lights harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Electrical schema - Auxiliary headlights harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Electrical schema - Telematics harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Electrical schema - ROPS2D harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Electrical schema - Tachograph harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Electrical schema - Printer ACE harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Electrical schema - Heating harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Electrical schema - Registration plate lighting harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Electrical schema - ACE FORCE connectors harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Electrical schema - ACE FORCE - sensor harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Electrical schema - ACE FORCE - Display harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Electrical schema - Compactometer ACD harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Electrical schema - Direction indicator lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

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Electrical schema - Direction indicator lights harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Electrical schema - Spotlight harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Fuse and relay box Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

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Electrical systems - Harnesses and connectors

Harnesses and connectors - Overview - Best practice Electrical failure modes Short Circuit A short circuit is a connection of comparatively low resistance between two points in an electrical circuit. Typically, when a higher source (positive supply) short circuits to a ground circuit or a frame ground, it causes the circuit protection device, e.g. a fuse, to open and protect the wiring from damage. However, a short circuit can cause damage to the wiring and machine. This damage can occur if a circuit is not properly protected with a circuit protection device.

The amount of current allowed to flow through a wire due to a short circuit can cause the wire to overheat. This heat melts the insulation around the wire, adjacent wires, and may lead to a fire. Proper fusing reduces or eliminates damage to the machine resulting from a short circuit. A short circuit may result when a cut, pinched or chafed wire makes contact with a grounded component of the vehicle.

Open Circuit An open circuit is a loss of connection between two points in a circuit. This condition creates infinite resistance between two circuits and usually results in the malfunction of an electrical component.

An open circuit may result from: • Pinched/cut wire(s) • Terminal(s) improperly seated in a connector • Poor/improper crimping • Corroded terminal(s) • Improperly connected Faston connector/ring terminal

Intermittent Circuit An Intermittent circuit is a condition in the circuit that caused random or repeated failures, and is usually caused by repeatedly opens or shorts in the circuit. In other words, the circuit makes and breaks contact intermittently.

An intermittent circuit may be caused by: • Pinched wire • Loose ring terminal • Improper seating of terminal(s) in a connector • Incomplete mating of connectors • Corroded terminals

Examples of common electrical problems Short circuit • The wires are pinched between two objects, e.g. a frame and bracket.

RAIL14SSL0590AA

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1

Electrical systems - Harnesses and connectors

Open circuit • A cut or broken wire.

RAIL14SSL0589AA

2

RAIL14SSL0595AA

3

RAIL14SSL0600AA

4

RAIL14SSL0601AA

5

Open circuit • There is no contact between the wire(s) and the terminal due to the insulation not being properly removed or positioned when the terminal was fastened to the wire(s) .

Open circuit • Completely disconnected connectors do not make contact with the terminals.

Open circuit • The terminal is not positioned properly or did not stay inside the connector.

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Electrical systems - Harnesses and connectors

Open circuit • A wire is missing from a connector.

RAIL14SSL0602AA

6

RAIL14SSL0603AA

7

RAIL14SSL0593AA

8

RAIL14SSL0594AA

9

Open circuit • A wire length that is shortened.

Intermittent circuit • The hardware used to secure the terminal is not completely tightened.

Intermittent circuit • The ring terminal is not secured with hardware.

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Electrical systems - Harnesses and connectors

Intermittent circuit • The terminal is not crimped on the wire(s).

RAIL14SSL0596AA

10

RAIL14SSL0597AA

11

RAIL14SSL0598AA

12

RAIL14SSL0599AA

13

Intermittent circuit • Bent pins may cause a short circuit if the two terminals do not contact.

• The male and female connectors may not make contact because of the bent pin.

Intermittent circuit • Corrosion on the pin(s) is Indicated by a layer of greenish-white powder appearing on the pins.

• Corroded pins may overheat because of increased resistance due to corrosion.

Intermittent circuit • Partially disconnected connectors make contact with only some terminals.

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Electrical systems - Harnesses and connectors

Intermittent circuit • Cracked, broken or melted connector cause improper connections.

RAIL14SSL0605AA

14

RAIL14SSL0606AA

15

RAIL14SSL0591AA

16

RAIL14SSL0592AA

17

Intermittent circuit • A ground terminal not fastened or loose on the machine.

Chaffed wire • A section of the wire’s insulation is rubbed away, exposing the bare wire.

Burned wire and/or melted insulation • If the wire(s) are located near a heat source or overheated because of continuous, excessive current, the insulation will be discolored and melt, exposing the wire(s).

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Electrical systems - Harnesses and connectors

Cross connection • Terminals that are connected in the wrong cavity will result in system malfunction.

RAIL14SSL0604AA

18

RAIL14SSL0607AA

19

Incorrect routing • A wiring harness not routed properly can lead to problems.

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Electrical systems - Harnesses and connectors

Prevention of common electrical problems In order to prevent common problems and to achieve a higher reliability, please follow the below procedures. Please use harness diagnostic and repair kit, part number 380040185, to assist you with repairs to wires, harnesses, and connectors.

Sealed connectors Sealed connectors are designed with weather-proof seals that protect the connector’s terminals from moisture and debris. This protection makes them ideal for use on the exterior. Two types of seals are available in these types of connectors: • A connector seal which provides an environmental seal between the mating connectors.

• A cable seal which seals the area where each wire enters the connector.

RAIL14SSL0609AA

20

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Electrical systems - Harnesses and connectors

Unsealed connectors Unsealed connectors are designed for the interior of the machine where connectors are free from contaminates. Do not replace sealed connectors with unsealed connectors. Usage of unsealed connectors in place of sealed connectors could lead to damage by environmental factors such as moisture and debris, and cause corrosion which can lead to a poor connection. Corroded terminals create high resistance in the connection, which can cause intermittent or open circuits.

RAIL14SSL0608AA

21

Assembly and disassembly of connectors: Crimping wires on the terminals The crimping procedure is the same for sealed and unsealed connectors. The differences are identified below.

Sealed connector 1. Slide the wire seal (1) on the wires.

RAIL14SSL0610AA

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22

Electrical systems - Harnesses and connectors

2. Remove approximately 10 mm (3/8 in) insulation from the wire ends.

3. Inspect wire strands for cuts and damage. Remove the stripped portion of wire and strip again if necessary.

RAIL14SSL0611AA

23

RAIL14SSL0613AA

24

RAIL14SSL0611AA

25

RAIL14SSL0612AA

26

4. Place the wire (1) on the terminal. Verify that the wire seal (2) rests on the insulation barrel (3).

5. Verify that the wire core (4) is exposed to the wire barrel (5).

Unsealed connector 1. Remove approximately 10 mm (3/8 in) insulation from the wire ends.

2. Inspect wire strands for cuts and damage. Remove the stripped portion of wire and strip again if necessary.

4. Place the wire (1) on the terminal. Verify that the insulation lies on the insulation barrel (2).

5. Verify that the wire core (3) is exposed to the wire barrel (4).

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Sealed and unsealed connectors 6. Use the appropriate tools to crimp the barrels. Follow these precautions while crimping: A. Do not bend or crack the terminal.

B. Do not cut the wire strands with the barrel.

C. Verify that all wire strands are contained inside the core barrel.

D. Wires must not fall out of the barrels once they have been crimped.

RAIL14SSL0614AA

27

RAIL14SSL0615AA

28

7. Solder all hand-crimped terminals.

8. Check circuit for electrical continuity.

Installing terminals in the connectors NOTICE: Installing the terminals do not require any special tools. Do not use excessive force to insert a terminal.

1. Orient the terminal to its proper relationship with the connector body.

2. Insert the terminal into the correct connector cavity.

3. Push until the terminal “clicks” in place.

4. Gently pull the wire back to ensure the proper seating of the terminal. Verify that the terminal will not back out from the connector.

RAIL14SSL0616AA

29

RAIL14SSL0617AA

30

Wires are locked in place with a wire lock or a Terminal Position Assurance (TPA) lock.

Wire locks or TPA locks are added in the connector to avoid damage to the wires as the exposed/loose wires are more prone to damage.

Wire locks and TPA locks vary in size and shape, depending on the type of connector being used.

Some connectors may not have wire or TPA locks.

NOTE: Image shows connector without wire lock.

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Electrical systems - Harnesses and connectors

Sealed connector - wire lock 1. Install the wire lock after all terminals have been seated in the connector.

2. Push the lock over the back of the connector until it locks onto the connector.

RAIL14SSL0619AA

31

RAIL14SSL0618AA

32

RAIL14SSL0620AA

33

Unsealed connector - TPA lock 1. Install the TPA lock after all terminals have been seated in the connector.

2. Push the lock into the back of the connector until it locks into place.

Hinged wire lock 1. On connectors with a hinged wire lock, snap the wire lock over back of the connector .

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Prior to mating the connectors, visually inspect the connectors for damage. Verify that the connector pins are straight.

RAIL14SSL0621AA

34

RAIL14SSL0622AA

35

RAIL14SSL0623AA

36

Bent pins will lead to damage to the connector and may cause a short circuit.

Once the terminals are installed and locked in place, apply dielectric grease to the connector and on the pins to avoid corrosion.

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1. Push the connectors together until the connector’s locks snaps into place.

2. If a manual latch is present, secure the manual latch.

3. Slightly pull the connectors to verify a proper connection.

NOTICE: Do not test the connectors by pulling the wires.

RAIL14SSL0624AA

37

RAIL14SSL0625AA

38

RAIL14SSL0626AA

39

RAIL14SSL0627AA

40

Precautions to be followed while connecting a connector: • Verify that the connections are intact. Loose connections will lead to disconnection and corrosion damage.

• Rubber seals on the connector prevents contamination.

Verify that the seal is present on the connectors before mating the connectors.

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• On connectors with a missing seal, the connection will not be intact and may cause intermittent or open circuit.

RAIL14SSL0628AA

41

RAIL14SSL0629AA

42

RAIL14SSL0630AA

43

RAIL14SSL0631AA

44

• Verify that the connectors without internal locks, the “T” on the pins are flush with the bottom of the mating connector to ensure a proper connection.

• Image 43 shows properly mated connector.

• In regards to Engine Control Unit (ECU) connectors, verify that the connector is properly locked. Moving the lever towards the controller locks the connector Moving the lever away from the controller unlocks the connector. When the connector is properly locked, you should be able to feel the lever “click” into place.

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• Install the secondary locks or connector position assurance (CPA) locks as required.

RAIL14SSL0632AA

45

RAIL14SSL0633AA

46

RAIL14SSL0634AA

47

RAIL14SSL0635AA

48

NOTICE: Missing and improperly installed secondary locks will lead to faulty connections.

Disconnecting connectors 1. Remove the secondary lock or CPA lock as follows: ○ Depress the tabs on either side of the lock ○ Pull the lock out of the connectors.

2. With your thumb and a small screwdriver or a pick, lift the connector’s lock and pull the connectors apart.

NOTICE: Do not disconnect the connectors by pulling the wires.

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Unsealed connector – TPA lock removal 1. With a screwdriver or pick, depress the locking tabs of the TPA lock and pull the lock from the connector.

NOTE: If the locks and connectors are to be used again, verify that the locking mechanisms are not bent or deformed.

RAIL14SSL0636AA

49

RAIL14SSL0637AA

50

Sealed connectors – Wire lock removal 1. With a screwdriver or pick, lift the secondary lock over the locking tabs on either side of the connector and remove the lock from the connector.

NOTE: If the locks and connectors are to be used again, verify that the locking mechanisms are not bent or deformed.

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Removal of terminals from the connectors Special tools are required to remove the terminal without damaging it or the connector in which it is inserted. Please use harness diagnostic and repair kit, part number 380040185, to assist you with repairs to wires, harnesses, and connectors.

Because connectors are designed to firmly retain terminals, it is sometimes difficult to remove the terminals.

Different style terminals have different removal procedures, but the most common terminals can be removed by using the procedure below.

A terminal removal tool (Ex: pick or safety pin) is required to remove a push-to-seat terminal from a connector.

1. Disconnect the mating connector.

2. Remove any wire or TPA lock.

3. Grasp the wire (3) and push the terminal to the foremost position in the cavity of the connector (2). Hold the terminal in this position.

4. The terminal locking tang should be separated from the ridge inside the connector cavity. This makes it easy for the terminal removal tool (1) to unseat the terminal.

5. Locate the terminal lock tang in the connector cavity channel by looking into the connector from the mating end.

RAIL14SSL0638AA

51

6. Insert an appropriately sized pick into the connector cavity from the mating end of the connector.

7. Depress the lock tang with the pick or pin to unseat the terminal.

8. Gently pull the wire to remove the terminal through the back of the connector.

NOTICE: If force is required to remove the terminal, the locking tang has not been properly depressed. Forcing a terminal out of the connector can damage the cavity walls.

Splicing To ensure a reliable connection, CNHi does not recommend the use of Quicksplice, Scotchlock, wire nuts, and/or similar splicing devices.

A crimp and seal splice sleeve is recommended for splicing two wires together.

The advantages of using a crimp-and-seal splice sleeve are as follows: • Easy to use.

• Only one part is required to complete the splice.

• Does not require soldering.

• Suitable for use in the interior and exterior of the machine.

• The bond between the splice and the wire, in addition to the wire crimp, creates a very strong splice.

When heated, these splices have a glue-lined sleeve that shrinks over the wires to seal them.

For reliable splicing, always select properly sized splice sleeve as per the wire gauge of the wires to be spliced.

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Recommended splicing procedure Splicing single wires 1. Strip off approximately 10 mm (3/8 in) insulation from the wire ends.

RAIL14SSL0639AA

52

RAIL14SSL0640AA

53

RAIL14SSL0641AA

54

RAIL14SSL0642AA

55

2. Push the wire cores into the sleeve till they reach the stop at the center of the sleeve.

3. Individually crimp both the ends of the splice sleeve.

4. With a hot air gun, apply heat to the splice sleeve.

5. Heat will melt the glue and adds a firm seal. When the sleeve stops shrinking and glue appears at the ends of the sleeve, remove the heat source.

6. Allow the splice to cool.

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Splicing multiple wires CNHi recommends the use of splice clip for splicing two or more wires together.

Splice clips are similar to terminal core grip wings, except that the splice clips accept more than one wire.

1. Strip off approximately 10 mm (3/8 in) insulation from the wire ends.

RAIL14SSL0643AA

56

RAIL14SSL0644AA

57

RAIL14SSL0645AA

58

2. Place the stripped wires in the splice clip.

3. Crimp the splice clip.

NOTICE: Do not crimp the insulation.

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4. Heat the splice clip with a soldering iron and apply solder to the splice clip.

5. Do not use too much solder. Too much solder might lead to wicking and makes the wire brittle, resulting in wire damage.

6. Check the continuity of the spliced wires.

7. Cover the splice with splice tape or heat shrink tubes.

RAIL14SSL0646AA

59

Harness routing guidelines Proper harness routing must be performed to ensure the electrical system reliability. Improper routing of the harness may lead to various electrical system malfunctions.

When repairing or replacing wire harnesses, verify that the harnesses are routed in their original position. Observe the following safety precautions while routing the harness.

Location Verify that the harness: • Should not come in contact with any moving parts.

• Should be placed at least 125 mm (5 in) away from sources of radiant heat • Should be away from any potentially damaging surfaces, such as sharp or abrasive objects, sheet metal holes, sharp metal flanges, etc.

• Should be placed at least 75 mm (3 in) away from battery vents

RAIL14SSL0647BA

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60

Electrical systems - Harnesses and connectors

Verify that the bare wires (without conduit) do not contact the hydraulic tubes and hoses.

RAIL14SSL0648AA

61

RAIL14SSL0649AA

62

RAIL14SSL0650BA

63

Verify that the bare wires are not secured with cable ties.

Tension Verify that the harness is not under tension. Tension is when the strain on the harness between two fixing points (clamps, brackets, connectors, grommets, etc) is larger than the weight of the wiring harness.

Verify that the slack between two fixing points is not going to cause interference with other objects/moving parts.

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When the harness are to be bent, verify that the bend radius is equal to or more than three time the harness diameter.

RAIL14SSL0651AA

64

RAIL14SSL0652AA

65

RAIL14SSL0653AA

66

Image 65 is an example of a correct bend radius.

Image 66 is an example of an incorrect bend radius.

Harness fastening guidelines The wiring harness must be fastened properly to avoid any possible harness damage such as incorrect routing, pinching, entrapment, and/or other conditions which would damage the wiring harness.

When installing the harness, follow their original routing positions and locations. Follow the guidelines below to verify that the harness is fastened properly.

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Use the double tie to secure the wiring harness to isolated points on the machine.

RAIL14SSL0654AA

67

RAIL14SSL0655AA

68

RAIL14SSL0657AA

69

RAIL14SSL0658AA

70

Use the dual clamp to secure the harnesses without any contact.

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Grounding guidelines A return path is necessary in an electrical circuit. In CNHi applications, the ground points are equivalent to the battery negative terminal.

The electrical system should be properly grounded.

Use plated ground fasteners (studs, ring terminals, etc.) for better corrosion resistance.

The ground fasteners must be compatible with the ground terminals to reduce galvanic corrosion. Do not use rivets or sheet metal screws for grounding.

Grounding surfaces must be free of sealants, paint and/or any non-conductive coatings.

Whenever possible, use ring terminals with an anti-rotation feature. In case of terminals without an anti-rotation feature, use lock washers.

RAIL14SSL0701AA

71

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Wiring harnesses - Electrical schema - Electrical schema key NOTE: Seat switch; Engine Tier 4B (final); ATC MODULE; MURPHY Power View gauge (the schematic reflects machine version that includes all controlling elements and accessories) Item A1

A2 A3 A4

A5

A6 B2

B3

B5 B6

Description Clicker for direction-indicator lights Electronics to secure travel Travel actuator – Gessman lever Multifunctional display Murphy PV - 101 Fan Drive control unit Engine control unit (ECM) Hydraulic oil thermometer sensor Hydraulic oil temperature sensor Float in fuel tank

Item H18

H19 H20 K2-11

K12

Description Pilot lamp for engine oil Pilot lamp for engine coolant Pilot lamp for diagnostics Auxiliary relays

Item

S30

Description Vacuum switch for hydraulic oil filter clogged Cab fan selector switch Front wiper switch

S31

Rear wiper switch

S28

S29

K13 M1

Engine starter

S34

M2

Motor for cab lifting pump

S36

Switch to reduce drum slip

M3

Cab ventilation fan Front wiper

S38

Rear wiper

S40

Coolant level indicator Diagnostics button ATC switch

Windscreen washer Rear glass washer

S41

V2,4 -7 V8-11

E2,3

Engine RPM M4 control Hydraulics M5 thermometer lighting Front fender lights M6

E4,5

Rear lamps

M7

E6,7 E8,9

Front headlights Rear headlights

M8 M9

Heater fan Fuel pump

E10,11

P2

E14

LH directionindicator lights RH directionindicator lights Cab lighting

R1.1,1.4

Hydraulic oil X2-24 thermometer Battery X27 disconnector Engine preheating X28-33

E15

Hazard beacon

R4,5

Resistor

E16,17

Brake lights

S1

E18

Registration plate S2 lighting

F1-12

Drop-out fuses

Cab lifting double X36-46 pushbutton Bonnet X64 lifting double pushbutton Ignition box X50-53

E1

E12,13

Washers double pushbutton

Starter contactor S32 (engine component) Glowing contactor S33

Q1

S3

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S39

V3

X34

Heater fan selector switch Auxiliary headlights switch

Water in fuel indicator Interlocking LED (only with Machines having cab lifting alarm) Interlocking LEDs Suppression diode Interface connectors Socket for hazard beacon Interface connectors Socket for engine diagnostics J1939 Connector Diagnostic socket

Splitter connectors (Wago)

Electrical systems - Harnesses and connectors

Item F21-23

Description Drop-out fuses

S4

G1,2

Batteries

S5

G3

Alternator

S6

H1

S7 Pilot lamp for direction-indicator lights

H2

Horn

S8

H3

Backing horn

S9

H4

Pilot lamp for hydraulic oil level Pilot lamp for neutral Pilot lamp for brake Pilot lamp for vibration preset

S11

H5 H6 H7

H10 H11

H12

H13 H17

Item

S14 S16

Description Front headlight switch Rear headlight switch Warning light switch Directionindicator light change- -over switch Hazard beacon switch Horn pushbutton

Item Y1 Y2 Y3 Y4

Y6 Y7

Emergency brake Y8 pushbutton Float inside Y9 hydraulic oil tank Fast travel switch Y10

S17

Selector switch for Y11 operating speed preset

Pilot lamp for S18 battery recharging Pilot lamp for air S19 filter clogged

Vibration selector Y13 switch Vibration switch Y14 (in travel actuator)

Pilot lamp for hydraulic oil filter clogged Fan Drive Error pilot lamp Pilot lamp for glowing

S21

Brake pressure switch

S22

Seat switch

S27

Vacuum switch for air filter clogged

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Y15

Description Solenoid valve for cab lifting Solenoid valve for cab lowering Solenoid valve for bonnet lifting Solenoid valve for bonnet lowering

Solenoid valve for brake Solenoid valve for fast travel - LH wheel Solenoid valve for fast travel - drum Solenoid valve vibrations 1 Solenoid valve for vibrations 2 Solenoid valve to disengage RTM module differential interlock Servo valve for travel pump Solenoid valve for fast travel - RH wheel Fan Drive proportional valve

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schema - Electrical schema - 01

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RAIL18COM0001JA

1

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Wiring harnesses - Electrical schema - Electrical schema - 02

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RAIL18COM0002JA

1

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Wiring harnesses - Electrical schema - Electrical schema - 03

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RAIL18COM0003JA

1

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schema - Cable harness number 1 - Main harness Part 1

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RAIL18COM0007JA

1

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Wiring harnesses - Electrical schema - Cable harness number 1 - Main harness Part 2

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RAIL18COM0008JA

1

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Wiring harnesses - Electrical schema - Cable harness number 2

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RAIL18COM0009JA

1

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Wiring harnesses - Electrical schema - Cable harness number 3 - Part 1

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RAIL18COM0010JA

1

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Wiring harnesses - Electrical schema - Cable harness number 3 - Part 2

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RAIL18COM0011JA

1

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Wiring harnesses - Electrical schema - Cable harness number 3 - Part 3

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RAIL18COM0012JA

1

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schema - Cable harness number 4 - Armrest

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RAIL18COM0013JA

1

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schema - Cable harness number 5 - Wipers, washers, overhead light

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RAIL18COM0014JA

1

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Wiring harnesses - Electrical schema - Cab and hood harness

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Electrical systems - Harnesses and connectors

RAIL18COM0015JA

1

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schema - Wheel differential lock harness

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Electrical systems - Harnesses and connectors

RAIL18COM0016JA

1

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schema - Interaxle differential lock ATC harness

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Electrical systems - Harnesses and connectors

RAIL18COM0017JA

1

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schema - Front headlights harness

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Electrical systems - Harnesses and connectors

RAIL18COM0018JA

1

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Wiring harnesses - Electrical schema - Rear lights harness

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RAIL18COM0019JA

1

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Wiring harnesses - Electrical schema - Auxiliary headlights harness

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Electrical systems - Harnesses and connectors

RAIL18COM0020JA

1

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Wiring harnesses - Electrical schema - Telematics harness

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RAIL18COM0021JA

1

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Wiring harnesses - Electrical schema - ROPS2D harness

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RAIL18COM0022JA

1

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Wiring harnesses - Electrical schema - Tachograph harness

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Electrical systems - Harnesses and connectors

RAIL18COM0023JA

1

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Wiring harnesses - Electrical schema - Printer ACE harness

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RAIL18COM0024JA

1

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Wiring harnesses - Electrical schema - Heating harness

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RAIL18COM0025JA

1

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Wiring harnesses - Electrical schema - Registration plate lighting harness

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RAIL18COM0026JA

1

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Wiring harnesses - Electrical schema - ACE FORCE connectors harness

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RAIL18COM0027JA

1

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Wiring harnesses - Electrical schema - ACE FORCE - sensor harness

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RAIL18COM0028JA

1

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Wiring harnesses - Electrical schema - ACE FORCE - Display harness

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Electrical systems - Harnesses and connectors

RAIL18COM0029JA

1

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Wiring harnesses - Electrical schema - Compactometer ACD harness

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RAIL18COM0030JA

1

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Wiring harnesses - Electrical schema - Direction indicator lights

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Electrical systems - Harnesses and connectors

RAIL18COM0031JA

1

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Wiring harnesses - Electrical schema - Direction indicator lights harness

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Electrical systems - Harnesses and connectors

RAIL18COM0032JA

1

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Wiring harnesses - Electrical schema - Spotlight harness

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RAIL18COM0033JA

1

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Fuse and relay box - Identification WARNING Avoid injury!

Shut off the engine, remove the key, and make sure all motion is stopped before servicing the machine.

Failure to comply could result in death or serious injury.

W1128A

NOTE: Always replace the fuses with ones of identical value.

RAIL17COM0104AA

F1

Rating 20 A

F2

20 A

F3

10 A

F4 F5

7.5 A 15 A

F6 F7

7.5 A

F8

7.5 A

1

RAIL17COM0125AA

Description (upper fuse) switch box, relay coil K11 front- -end to fuses F7, F8, F9 front parking lights, rear lights, license plate lighting, front headlamps, rear headlamps, additional headlamps, cab lifting control turn indicators, beacon, horn, internal cab lighting fuel pump, time relay coil A10 wipers, glass washers, heating ventilator spare (air conditioning) reverse horn, travel locking electronics, travel control lever, vibration, travel, brake lights, hydraulic oil level hydraulic oil temperature, hydraulic oil filter, charging, Fan Drive electronics

2

F9

Rating 1A

F10

—

F11

15 A

power supply of engine electronics

F12 F21

3A 50 A

F22 F24

60 A 125 A

engine of cab lifting pump and bonnet (optional) electro-hydraulic aggregate of hood lifting, hood lowering and driver’s stand main fuse engine heating

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Description Power View display —

Index Electrical systems - 55 Harnesses and connectors - 100 Wiring harnesses - Electrical schema - Electrical schema - 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32

Wiring harnesses - Electrical schema - Electrical schema - 03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34

Wiring harnesses - Electrical schema - Cable harness number 1 - Main harness Part 1 . . . . . . . . .

36

Wiring harnesses - Electrical schema - Cable harness number 1 - Main harness Part 2 . . . . . . . . .

38

Wiring harnesses - Electrical schema - Cable harness number 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40

Wiring harnesses - Electrical schema - Cable harness number 3 - Part 1 . . . . . . . . . . . . . . . . . . . . . .

42

Wiring harnesses - Electrical schema - Cable harness number 3 - Part 2 . . . . . . . . . . . . . . . . . . . . . .

44

Wiring harnesses - Electrical schema - Cable harness number 3 - Part 3 . . . . . . . . . . . . . . . . . . . . . .

46

Wiring harnesses - Electrical schema - Cable harness number 4 - Armrest . . . . . . . . . . . . . . . . . . . .

48

Wiring harnesses - Electrical schema - Cable harness number 5 - Wipers, washers, overhead light

50

Wiring harnesses - Electrical schema - Cab and hood harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52

Wiring harnesses - Electrical schema - Wheel differential lock harness . . . . . . . . . . . . . . . . . . . . . . . .

54

Wiring harnesses - Electrical schema - Interaxle differential lock ATC harness . . . . . . . . . . . . . . . . .

56

Wiring harnesses - Electrical schema - Front headlights harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58

Wiring harnesses - Electrical schema - Rear lights harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60

Wiring harnesses - Electrical schema - Auxiliary headlights harness . . . . . . . . . . . . . . . . . . . . . . . . . .

62

Wiring harnesses - Electrical schema - Telematics harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64

Wiring harnesses - Electrical schema - ROPS2D harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

66

Wiring harnesses - Electrical schema - Tachograph harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68

Wiring harnesses - Electrical schema - Printer ACE harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70

Wiring harnesses - Electrical schema - Heating harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72

Wiring harnesses - Electrical schema - Registration plate lighting harness . . . . . . . . . . . . . . . . . . . . .

74

Wiring harnesses - Electrical schema - ACE FORCE connectors harness . . . . . . . . . . . . . . . . . . . . .

76

Wiring harnesses - Electrical schema - ACE FORCE - sensor harness . . . . . . . . . . . . . . . . . . . . . . . .

78

Wiring harnesses - Electrical schema - ACE FORCE - Display harness . . . . . . . . . . . . . . . . . . . . . . .

80

Wiring harnesses - Electrical schema - Compactometer ACD harness . . . . . . . . . . . . . . . . . . . . . . . .

82

Wiring harnesses - Electrical schema - Direction indicator lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84

Wiring harnesses - Electrical schema - Direction indicator lights harness . . . . . . . . . . . . . . . . . . . . . .

86

Wiring harnesses - Electrical schema - Spotlight harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

88

Fuse and relay box - Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

91

Harnesses and connectors - Overview - Best practice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Wiring harnesses - Electrical schema - Electrical schema - 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30

Wiring harnesses - Electrical schema - Electrical schema key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28

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Electrical systems - 55 Engine starting system - 201

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Contents Electrical systems - 55 Engine starting system - 201

FUNCTIONAL DATA Engine starter Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - Engine starting system

Engine starter - Static description • Correct operation of the starter is preconditioned by correct and fully charged batteries.

• The starter has been designed for a short-period operation of less than 5 seconds.

• When the engine starts, stop starting, otherwise the pinion and/or the bearing may be damaged.

• Cables must be tight, the insulation must not be damaged.

• The starter body is part of the circuit. Keep contact faces on the engine clean and protected against corrosion.

• Should the starter be inoperative, look for breaks between the battery and the starter, the engine and the starter, or the chassis and the batteries.

• Check the crown of the flywheel and the pinion for wear, and apply grease at the same time.

• During repair or every 2 years remove the starter, check the commutator, the brush springs, and the breaker contacts.

The brushes must sit with a 3/4 surface on the commutator ring and must be easily sliding. The contact areas of the breaker must not be burnt, and must make contact for the entire flat part.

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Index Electrical systems - 55 Engine starting system - 201 Engine starter - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3

Electrical systems - 55 Alternator - 301

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Contents Electrical systems - 55 Alternator - 301

FUNCTIONAL DATA Alternator Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Alternator - Static description • The alternator is the source of electrical energy.

• A semiconductor voltage regulator is part of the alternator to maintain output voltage within limits while the revolutions, load, and ambient temperature vary.

• Regulated voltage is measured on terminal +B. • The alternator must always be connected to the battery – positive battery to +B. It is not allowed to disconnect the battery while the engine is running.

• Avoid shorts in the alternator circuit. While repairing wiring or welding on the machine, disconnect the alternator.

When starting with an external source, it is not permitted to disconnect this source when the battery is not yet on.

The alternator must not be run unloaded with the cable removed from terminal ”+B” and terminal ”+D” connected.

• A burnt-out indicator bulb of charging must be replaced immediately. Without this bulb the alternator excitation doesn’t function. When washing the engine, prevent water from entering the ventilation openings on the alternator.

NOTE: When welding on the machine, disconnect the alternator leads from terminals ”+B” and ”+D”, and electrical devices containing semiconductors. Disconnect the battery when repairing other electrical devices.

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Index Electrical systems - 55 Alternator - 301 Alternator - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3

Electrical systems - 55 Electronic modules - 640

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Contents Electrical systems - 55 Electronic modules - 640

FUNCTIONAL DATA Controller Area Network (CAN) data bus Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - Electronic modules

Controller Area Network (CAN) data bus - Dynamic description Introduction CAN is an acronym for Controller Area Network. The bus connects controllers on a machine, and allows information to be shared between the controllers. CAN was first developed by Bosch and Intel in 1984, and has been in use in the automotive and truck industry since the late 1980‘s. Applications of CAN follow guidelines that are established in SAE J1939.

Glossary of terms Bus CAN CAN HI CAN LO Controller

Terminator

The network, e.g. the wires, connectors, and terminators between the controllers.

Controller Area Network. Generally refers to all parts of the system -the controllers, wires, and terminators.

A high priority, message carrying wire on the CAN bus.

A low priority, message carrying wire on the CAN bus.

Components that are connected by the bus and share information. May also be referred to as processors, control modules, units, or modules.

An electrical resistor or circuit placed at either end of the bus. They may be passive or active type. They may be a separate component or part of a controller. Terminators prevent a message from rebounding along the bus, clear the bus for the next message, and allow clear messages to travel the bus.

Purpose In the past, if a speed sensor‘s information was needed by a tachometer, an engine controller, and a transmission, the three devices would need to be wired to the speed sensor. The complexity of wiring can be greatly reduced through the use of a CAN bus system. A controller sends the speed sensor data onto the bus, and the other controllers on the bus can read the data. Any controller on the bus that does not care about the data will ignores the message.

A CAN bus system also offers improved diagnostics with the use of the Electronic Service Tool (EST). The controllers can detect errors, and fault codes can be displayed to the operator and technician. Onboard diagnostics may provide the ability to test and monitor circuits during operation, aiding in troubleshooting.

The advantage of a CAN bus system are: 1. A decrease in the number of wires and overall length of the wiring harness.

2. Information is received by one controller which shares the information with the other controllers on the bus.

3. Less wiring and fewer connectors improve reliability and durability.

4. Improved diagnostics with the EST.

Operation When the CAN bus is initially powered up (keyswitch on), each controller on the bus sends a message announcing its existence and looks for messages from other controllers on the bus. After this initial message, each controller sends data messages as necessary. The frequency of these messages is based on software programming, with important messages broadcast more frequently than low priority messages.

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Electrical systems - Electronic modules

RAIL13TR03931FA

1

If a controller has not sent any messages within five seconds, it will broadcast a message that announcing its existence. This is done in order to monitor each controller’s status on the bus. If a certain controller has not transmitted any messages for more than five seconds, then the other controllers on the bus will generate an alarm message indicating that a controller is offline.

NOTE: This offline status condition may vary from one machine type to another. Some machines may need to be configured to know that a specific controller is on the bus. However, this process of existence messages generally holds true.

In a CAN system, controllers are positioned near the majority of their sensors and switches. For example, the Engine Control Unit (ECU) is located in the engine compartment near the engine sensors. This results in less wiring, fewer connections, and a reduction in the number of error sources.

The voltage signal from sensors and switches are processed by a controller, which converts the signal to a data message. The data message is sent to the bus by the controller. Every controller that is connected to the bus can read and process the data message as required. Each controller knows which information it needs based on the software that is programmed into it.

The terminators absorb the voltage signals at either end of the bus. They are constantly trying to maintain of voltage of 2.5 V on the bus. Terminators prevent a signal from rebounding along the bus, clear the bus for the next signal, and allow clear messages to travel the bus.

Terminators Terminators help eliminate the reflections that can occur when a message reaches the end of the bus. These reflections can cause interference (noise) on a CAN bus, creating communication problems between the controllers.

A good way to explain how terminators work is to think about dropping a stone into a pond. After the stone hits the water, the waves travel to the edges of the pond and then rebound to the center. Terminators absorb the waves at the edges and deny the rebound of the waves to the source.

Passive terminator or active terminator 1. Passive terminators are usually 120 Ω resistors placed at either end of the bus. Passive terminators are typically used with a two wire CAN system. These resistors are connected between the CAN HI and CAN LO wires. Passive termination is popular because it is a fraction of the cost of active terminators. Passive terminators act as snubbers to kill reflections and work efficiently on systems with lower bus loading (low CAN bus traffic).

2. Active terminators are voltage regulators, and require a external voltage supply to operate. Active terminators are typically used with a four wire CAN system. Active terminators produce 2.5 V on the CAN HI and CAN LO wires to maintain the standard CAN wire voltage. This means they bring the wires to neutral. Active terminators are very efficient, and are typically used on systems with high bus loading (high traffic).

Troubleshooting The CAN system is capable of diagnosing itself and generating an alarm messages to the operator when problems are present. The vehicle may continue to function when an alarm messages appears, but the systems related to that controller may no longer function. When troubleshooting a vehicle with suspected CAN system failure, it is important to determine if the problem is related to one or more controllers or if the bus is at fault.

CAN system problems will generally fall into two categories: 48150518 26/02/2018

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Electrical systems - Electronic modules

1. Problems with individual controllers that affect certain functions, such as transmission or engine operation.

2. Problems with the bus. (The wires between the controllers.)

Some questions to answer are: 1. What functions are affected?

2. Are the affected functions related to a specific controller or several different controllers?

3. Are there any error codes or alarm messages active?

4. Are the error codes and/or alarm messages related to a specific controller or are they indicating an fault with the entire system?

If only one or two controllers are affected on the vehicle, then those controllers should be tested for faults before suspecting a CAN bus failure.

There are two general conditions that may cause an individual controller to go offline.

1. Loss of power or ground to the controller.

2. Controller related faults, such as a CAN controller failure, poor or failed CAN connector, or message errors.

Loss of power or ground The controllers are not powered through the CAN bus wires. Each controller requires a power supply and ground supply. If power or ground is lost, the controller will deactivate and will not be active on the bus. In addition, most controllers require a minimal voltage level to activate, so weak batteries, a faulty charging system, or poor connections may prevent controllers from properly activating.

Controller faults Whenever a controller transmits or receives a fault message, it keeps a record of that error. After its error history fills, the controller assumes that it is faulty, and will stop transmitting on the bus. We describe this situation as a controller that has gone “bus off,” which may cause an alarm message to be displayed. This error history is erased and reset at zero when the controller is deactivated.

There are several CAN related faults that may cause a controller to go offline: 1. External problems like bad or open connections to the CAN HI wires and CAN LO wires as a result of damaged wiring. Inspect the wiring for damage, and use a multimeter to check for continuity to the wires.

2. Internal problems like a failure of the controller itself. If the controller is activating but never communicates on the bus, the controller may have failed. If the controller is activating and is initially online but goes offline after a short period of operation, it may be in a bus off state.

Faulty messages may result from: 1. Failed terminators (signal reflection occurring) on the CAN bus. Test the terminators for proper operation.

2. Bad connections (e.g. loose pins, corroded terminals, damaged wires) between the controller and the bus.

3. A problem with the controller.

If several controllers are offline or the vehicle will not start, there may be a problem with the actual CAN bus. The wires may be shorted to 12 V, shorted to ground, open, or shorted together. Any of these problems can affect the entire CAN bus.

Testing the CAN bus There are several things to consider when testing CAN systems. The primary concern should be to confirm the integrity of the CAN bus circuit, after which you should check for shorts to battery voltage or to chassis ground.

You can easily test the CAN bus (CAN HI and CAN LO) for open circuits by conducting a circuit continuity check at the vehicle’s diagnostic connector. However, for vehicles that use active terminators, it is necessary to unplug those terminators, and replace them with jumper wires between the CAN HI wires and CAN LO wires.

For our machine, we deactivate all systems and use a multimeter (1) to check the resistance between pins C and D of our vehicle’s diagnostic connector (2).

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NOTE: The CAN circuit that is being tested must be connected to the diagnostic connector.

RAIL13TR03932FA

2

The resistance across the CAN circuit between CAN HI (3) and CAN LO (4) should be approximately 54 – 66 Ω. A reading of 54 – 66 Ω indicates that the passive terminators are good and confirms the integrity of the CAN bus circuit.

A reading of 70 – 150 Ω generally indicates that either a passive terminator has failed or there is an open circuit in either the CAN HI wires or CAN LO wires. You must perform additional testing to isolate the source of the fault.

A reading of infinite resistance indicate that either both passive terminators have failed or there is an open circuit in both CAN HI wires and CAN LO wires.

A reading of 53 Ω or less indicates poor connections in the circuit.

A reading of very low resistance indicates that the CAN HI wires and CAN LO wires are shorted together. Additional testing must be completed to determine the location of the short.

Testing the terminators If a passive terminator is suspected as a source of a CAN bus problem, disconnect the passive terminator from the CAN bus and test the resistance of passive terminators with a multimeter. Passive terminators should have a resistance of approximately 120 Ω.

NOTE: Some terminators may be an internal part of a controller. Disconnect the controller from the harness before testing.

Testing the CAN bus voltage A CAN circuit can be tested by testing the voltage of the CAN HI wires and CAN LO wires while the system is activated.

This test may provide some indication if the CAN circuit is shorted to high voltage or to ground, but is not conclusive of CAN system operation. If a fault is suspected, you must complete additional testing to locate the type and source of the fault.

Use a multimeter to check the voltage between either the CAN HI wires or CAN LO wire and chassis ground.

1. The CAN HI circuit should read approximately 2.5 – 3.5 V. 2. The CAN LO circuit should read approximately 1.5 – 2.5 V.

Testing the CAN bus for shorts to battery voltage If there is a short from a 12 V source to CAN HI or CAN LO, the controllers cannot send information on the CAN system.

With the keyswitch on, use a multimeter to check the voltage from the circuit to ground. This needs to be carried out for both the CAN HI and CAN LO wires. If data line voltage is at battery voltage, data can no longer be transmitted. If such an error is found on a data line, localize the error by opening the circuit at intermediate connectors and repeating this test.

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Testing the CAN bus for shorts between the wires If there is a short between the CAN HI wires and CAN LO wires, the controllers cannot send information on the CAN bus.

Turn the keyswitch off. Disconnect the terminators from the CAN HI wires and CAN LO wires, so the wires are open.

Use a multimeter to check for continuity between the CAN HI wires and CAN LO wires. If there is continuity, the two wires are shorted together. If such an error is found, localize the error by opening the circuit at intermediate connectors and repeating this test.

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Index Electrical systems - 55 Electronic modules - 640 Controller Area Network (CAN) data bus - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3

Electrical systems - 55 Cab controls - 512

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Contents Electrical systems - 55 Cab controls - 512

FUNCTIONAL DATA Joystick and Electric Hydraulic (EH) control Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Instrument cluster Replace - Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Replace - Murphy Power View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Electrical systems - Cab controls

Joystick and Electric Hydraulic (EH) control - Static description The travel controller may be fixed in position using an adjustable clamp. The travel controller operates also as a service and parking brake. The vibrator push button is located in the lever to be available for the interruption of vibrations any time.

SS13F061

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1

Electrical systems - Cab controls

Instrument cluster - Replace - Switch 1. Remove the steering wheel.

RAIL17COM0464AA

1

RAIL17COM0465AA

2

RAIL17COM0466AA

3

2. Remove the instrument panel.

3. Disconnect the wiring to the switch.

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Electrical systems - Cab controls

4. Remove the switch from the cover. Replace the switch.

RAIL17COM0467AA

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4

Electrical systems - Cab controls

Instrument cluster - Replace - Murphy Power View 1. Remove the steering-column shaft along with the steering wheel.

RAIL17COM0474AA

1

RAIL17COM0468AA

2

RAIL17COM0469AA

3

2. Pull out the shaft. Shaft end has dust cover put on.

NOTE: Unless you pull out the shaft complete with the dust cover (remains fitted on servosteering shaft), take it out.

3. Remove and fold up the instrument board. Before you remove it, disconnect the battery via master switch.

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Electrical systems - Cab controls

4. Unplug connector from socket (1), remove nut (2).

RAIL17COM0470AA

4

RAIL17COM0471AA

5

RAIL17COM0472AA

6

5. Connect new instrument and reassemble instrument board.

NOTE: Plug the connector to socket A when reassembling.

6. Reassemble the steering wheel. Before you reassemble, put the dust cover on shaft end.

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Electrical systems - Cab controls

7. Position the steering wheel so its handle is for left hand (the drum must be turned for straight-ahead driving).

RAIL17COM0473AA

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7

Index Electrical systems - 55 Cab controls - 512 Instrument cluster - Replace - Murphy Power View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Instrument cluster - Replace - Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Joystick and Electric Hydraulic (EH) control - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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. © 2018 CNH Industrial America LLC. All rights reserved.

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

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

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

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

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

48150518 26/02/2018 EN

SERVICE MANUAL Platform, cab, bodywork, and decals SV208D

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90

Contents Platform, cab, bodywork, and decals - 90

[90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 [90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2

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Platform, cab, bodywork, and decals - 90 Cab - 150

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Contents Platform, cab, bodywork, and decals - 90 Cab - 150

SERVICE Cab and platform Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Platform, cab, bodywork, and decals - Cab

Cab and platform - Raise WARNING Fall hazard!

The cab or platform must be empty when you lift the cab or platform, lower the cab or platform, and keep the cab or platform in the raised position.

Failure to comply could result in death or serious injury.

W1287B

CAUTION Avoid injury!

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

Failure to comply could result in minor or moderate injury.

C0079A

WARNING Avoid injury and/or machine damage!

Once lowered, secure the operator control stand (cab).

Failure to comply could result in death or serious injury.

W1117A

Electro-hydraulic control Raise the operator’s cab 1. Machines with a Roll Over Protective Structure (ROPS) canopy. Fold down the operator seat’s backrest and armrests before raising the cab.

SS12J311

1

SS12J314

2

2. Remove the cab’s mounting hardware located on the back side of the platform.

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Platform, cab, bodywork, and decals - Cab

3. Open the panel on the lower left-hand side of the machine.

RAIL17COM0211BA

3

RAIL17COM0126AA

4

4. Make sure that master disconnect switch (1) is in position I. 5. Press and hold the top side of the cab button (2) until the operator’s cab is fully raised.

Manual control Raise the operator’s cab NOTE: If the electric-hydraulic control is inoperative, or if the battery is discharged, raise or lower the cab by the adjustment of the distributors and with a hand pump as described in the following procedures. The distributors are located underneath the cab, inside the frame, on the left-hand side of the machine.

1. Machines with a Roll Over Protective Structure (ROPS) canopy. Fold down the operator seat’s backrest and armrests before raising the cab.

2. Remove the cab’s mounting hardware located on the back side of the platform.

SS12J314

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90.1 [90.150] / 4

5

Platform, cab, bodywork, and decals - Cab

3. Open the panel on the lower left-hand side of the machine.

RAIL17COM0211BA

6

RAIL17COM0127AA

7

RAIL17COM0217AA

8

4. Close the flow control valve on the distribution panel (A) by turning the screw (1) clockwise.

5. Remove the lever located behind the battery disconnect door, under the cab frame.

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Platform, cab, bodywork, and decals - Cab

6. Insert the lever into the coupler.

7. Move the lever back and forth to raise the cab.

8. Remove the lever after the cab is raised.

SS12J313

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9

Platform, cab, bodywork, and decals - Cab

Cab and platform - Lower Electro-hydraulic control Lower the operator’s cab 1. Open the side panel on the left-hand side of the machine.

RAIL17COM0211BA

1

RAIL17COM0126AA

2

RAIL17COM0211BA

3

2. Make sure that master disconnect switch (1) is in position I. 3. Press and hold the bottom half of the cab button (2) until the operator’s cab is fully lowered.

4. Close the side panel on the left-hand side of the machine.

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Platform, cab, bodywork, and decals - Cab

Manual control Lower the operator’s cab 1. Close the flow control valve on the distribution panel (A) by turning the screw (1) clockwise.

RAIL17COM0128AA

4

SS12J313

5

RAIL17COM0217AA

6

2. Insert the lever into the coupler.

3. Remove the lever after the cab is resting on the machine frame.

4. Secure the lever behind the battery disconnect door, under the cab frame.

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Platform, cab, bodywork, and decals - Cab

5. Close the panel on the lower left-hand side of the machine.

RAIL17COM0211BA

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7

Index Platform, cab, bodywork, and decals - 90 Cab - 150 Cab and platform - Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Cab and platform - Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

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Platform, cab, bodywork, and decals - 90 Engine hood and panels - 100

SV208D

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Contents Platform, cab, bodywork, and decals - 90 Engine hood and panels - 100

SERVICE Hood Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Platform, cab, bodywork, and decals - Engine hood and panels

Hood - Raise Electro-hydraulic control Raise the hood 1. Open the panel on the lower left-hand side of the machine.

RAIL17COM0211BA

1

RAIL17COM0126AA

2

2. Make sure that master disconnect switch (1) is in position I. 3. Press and hold the top side of the hood button (2) until the hood is fully raised.

Manual control Raise the hood NOTE: If the electric-hydraulic control is inoperative, or if the battery is discharged, raise or lower the hood by the adjustment of the distributors and with a hand pump as described in the following procedures. The distributors are located underneath the cab, inside the frame, on the left-hand side of the machine.

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Platform, cab, bodywork, and decals - Engine hood and panels

1. Open the side panel on the left-hand side of the machine.

RAIL17COM0211BA

3

RAIL17COM0127AA

4

SS12J313

5

2. Close the flow control valve on the distribution panel (B) by turning the screw (1) clockwise.

3. Remove the lever located behind the battery disconnect door, under the cab frame.

4. Insert the lever into the coupler.

5. Move the lever back and forth to raise the hood.

6. Remove the lever after the hood is raised.

7. Open the flow control valve on the distribution panel (B) by turning the screw (1) counter-clockwise.

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Platform, cab, bodywork, and decals - Engine hood and panels

Hood - Lower Electro-hydraulic control Lower the hood 1. Open the side panel on the left-hand side of the machine.

RAIL17COM0211BA

1

RAIL17COM0126AA

2

RAIL17COM0211BA

3

2. Make sure that master disconnect switch (1) is in position I. 3. Press and hold the bottom half of the hood button (2) until the hood is fully lowered.

4. Close the side panel on the left-hand side of the machine.

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Platform, cab, bodywork, and decals - Engine hood and panels

Manual control Lowering the hood 1. Close the flow control valve on the other side of the distribution panel (B) by turning the screw (1) clockwise.

RAIL17COM0128AA

4

SS12J313

5

2. Insert the lever into the coupler.

3. Move the lever back and forth to lower the hood.

4. Remove the lever after the hood is resting on the machine frame.

5. Secure the lever behind the battery disconnect door, under the cab frame.

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Platform, cab, bodywork, and decals - Engine hood and panels

Hood - Remove 1. Lift the bonnet using the switch.

RAIL17COM0226AA

1

RAIL17COM0227AA

2

RAIL17COM0228AA

3

2. Sling the rear part of the bonnet onto a crane.

3. Press out the pins of bonnet lifting linear hydraulic motors.

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Platform, cab, bodywork, and decals - Engine hood and panels

4. Mount lifting lugs on the front part of the bonnet, sling onto a crane. Remove the hinges.

RAIL17COM0229AA

4

RAIL17COM0230AA

5

5. Put the bonnet aside.

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Platform, cab, bodywork, and decals - Engine hood and panels

Hood - Install 1. Lower the bonnet into place.

RAIL17COM0230AA

1

RAIL17COM0229AA

2

RAIL17COM0228AA

3

2. Install the hinges using the hardware removed earlier.

3. Press in the pins of bonnet lifting linear hydraulic motors.

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Platform, cab, bodywork, and decals - Engine hood and panels

4. Remove the lifting sling.

RAIL17COM0227AA

4

RAIL17COM0226AA

5

5. Lower the bonnet into place using the switch.

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Index Platform, cab, bodywork, and decals - 90 Engine hood and panels - 100 Hood - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

Hood - Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Hood - Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Hood - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

48150518 26/02/2018

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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. © 2018 CNH Industrial America LLC. All rights reserved.

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

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

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

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

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

48150518 26/02/2018 EN

SPECIAL TOOL INDEX Genuine

Reference

380040185 [Harness Harnesses and connectors - Overview - Best practice Diagnostic /Repair Kit (NEF)] 380040185 [Harness Harnesses and connectors - Overview - Best practice Diagnostic /Repair Kit (NEF)]

48150518 26/02/2018

PAGE 55.2 / 10 55.2 / 20

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

SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 2018 CNH Industrial America LLC. All rights reserved.

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

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

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

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

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

48150518 26/02/2018 EN

12V 55Ah

12V 55Ah

Q1

M2 3

27

4

8 1 27

X7:1

X6.1:02

X4:3

X6.1:03

X8:8

X7:6

X6.1:13

X8:9

X7:31

X6.1:56

X8:10

X7:30

X6.1:55

X7:29

X6.1:53

10

S5

X9:2 X10:7

K86

X6.1:58 X7:33

K87

X6.1:32 X7:19

X30:4

X29:8

30

87

X6.1:51 X6.1:46 X6.1:47

5 10

K53 K64

K74

K57

K80

56 55 53

K35 K62 K63

K15

K54

K68

X7:26

P

S7

1

S6

2 8

5

6 1 5

3

49a

X6.1:17

1

S8

C B A

10

5

X6.1:05 X7:04

X10:3 X9:3

E11 X18:3

X3:7

X18:4

10A

Z

H1

X3:8

F3

X10:5 X9:5

S7 1 5

2 8

7

3

X10:4 X9:4

S6 6 49a 1 5 10

A1

49

31

X18:11,12

30

87a

K10

K75 K88

X6.1:09

X7:5 S

°C

H12

X5:8

X7:40

B

B3

-

85

86

87

30

F8 7.5A

P2 +

30

S11

F7

X22:1

7.5A

X11:2

2 1

C1:1

X19:4

C2:9 1 C1:3 2 C1:4

Y8

30

X4:6

V5

S36

1 9

2 1

1 M 2 F

5 10

K8

H G

B

2 21 1

F9

A

86 87

85 30

87a

87a 87 85

K7

30 86

1A

1 2

85

85

Y14 X4:5

X4:12

86

30

2 1

X12:2 X15:5

A3/2

86 87

A5

X4:4

H7

H5

Y7

2

H6 K5

C1:2

C1:9

CAN modul EM-5MA

2

X11:4

30

C2:2

2 7

F4

X22:2

1 86

1k

X19:3

Y15

H13

C1:8 C2:10

X19:2

A

X37

R5

X19:1

X43

87

X4:11

X18:5

E10

5 10

F3/ output C K5/ 87a S16/ 7

86

87

E16

86

X10:7

S5

3

85

85 87

2

1 9

E14

E13

K12

3B6

X6.1:57 X7:32

S28

30 85

H4 87a

X18:11,12

85

7.5A

K4

X3:11

X9:7

S18/ 5

S14

X4:3

V4

X11:1 86

X7:9 X20:3

X38

X3:12

K3

87

1

X5:3

C B A

5

9

S9

X8:6

87

30

K76

K53

X18:2

E12

X6.1:18 X7:10 X20:2

X36

49

31

1

X3:10

86

X6.1:24 X7:12

K2

H3

85

X6.1:22 X7:25

X7:8 X20:1

X10:2 X9:2

20A

3 10

X7:39

A1

10

X3:9

X22:1

K9

120

X6.1:23 X7:24

X6.1:16

X28

E9

R4

X6.1:49 X7:27

B2

F3

X10:5 X9:5

X4:10

X27

K75

X6.1:48

E6

X3:5

F2

2

S16/ 1,9

E15

K65

X7:20

X18:1

E8

H20

X6.1:33

E5

S4

6 8 1 9

E7

FAN DRIVE SSA MC024-014

H1

K70

E1

X7:38

7 X29:5

86

Z

X3:8

X30:3

9

E14

X3:7

X18:4

S34

85

10A

X29:4 X18:3

10

1

X9:7

K11

5

H17 H18

X6.1:29 X7:16

K46

X6.1:50

X6.1:28 X7:15

X10:1 X9:1

E4

X6.1:52 X7:28

X64

X28

E10

M9

X7:2

H19

X7:34

X34

X10:2

E20

H2

X8:7

X8:11

3

1

E9

E12

X2:1 2

9

E11

S41

20A

S4

6 8 1 9

X6.1:26

X29:2

X18:2

E19

L

87a

E8

X2:2

X15:3

X3:6

X3:4

E1

X7:14

K48

X6.1 Engine connector

X30:1

50a

F2

X29:1

E7

15/54

20A

X3:5

E6

S3

X6.1:25

K29

X6.2:28

K6

E18

30

Y

X29:3 X5:1,2

X18:1

F1

X26:1 X10:9 X9:8

E5

M

X6.1:37

X7:13

X3:2

Radio supply

X30:2

E4

E17

X7:21

K13

8

E2

E13

3(S) X8:4

4

X29:7

E3

K69

Engine diagnostic socket

Y4

X8:5

S27 P

X6.1:40

E3

X39

Y3

3

2(-)

X7:22

X8:2

K01 X6.2:07 K05

X40

S2

X8:3

W

L

S38

B

E2

X41

Y2

B

D+

1(+)

K06

D

X6.2:06

X42

1

G3

50A

S1

G

50

K02

A6

X8:1

60A

Y1

F21

30

F22

M

31

V3

X6.2:04

15A

R1.4

K12

X6.2:05

3A

R1.3

E

50

30

F11

R1.2

31

Y G F

V02 H10

70A

X6.2

G2

M

G1

Z

M L K J I H

M1

F24

F12

R1.1

K13

87a

X4:5

Y14

87a 87 85

X4:6

30 86

9 X12:2 X22:5 1

P

S21

8 2

X33:2

2

3

10 X22:7 X12:4,5 X51 5

X16:3

5

87

7

H7

K7

85

30 86

X4:9

X11:6

A

C M L K J I H

D

B

7 X52

X46:2

4 3

A3.1

8

(X13) 5 2

X12:4,5

1

A2 A3

6 X22:10 A4

SHEET 3

15A

S30

M4 X15:4

7

X15:2

1

5

SV208D T4B (Final)

M5

S31

X16:4

7

X16:1

1

M6

X17:1

S32

M7

X17:2

7 1

ELECTRICAL SCHEMATIC RAC 48150532

5

3

BATTERY POWER

S17

X46:3

A1

V8

5 1

X46:1 Z

G F

E

D

3

SWITCHED POWER

X5:12

X46:4

X22:8

STARTING SEQUENCE

S33

X5:11

M

X12:6

X12:7

Y13

F5

V10

M8 X22:9

X9:6

V9

6

S18

3

X10:6

X16:2

M M

1 X4:8

S16

4

1

X11:5

X4:7

Y10

5

6

X4:12

Y9

A3.2 (X14)

9

X22:6

Y8

K8

S29

5 1

M 7

A1

X15:1

12 10 11 B. horn

X4:4

A4

V11

M

10 8

Y7

M3

M

5

9

A6 MURPHY

X22:3 X12:3

4

Vibr.

1

3

S40

Vibr. Brake

15

X5:6

10

Neutr.

87 31

G

A3 A2

A5

X12:8

A7 30

S22

X33:1

X11:3

X5:4 87a

X11:7

Brake

Y11

12

Neutr.

8

1 11

A4

X5:5

Z

7

A2

X4:2

B5

X50

9

Electronics to secure travel

Y6

5 2

6

Air condition

X11:8

F6

B

X51

SHEET 1

SHEET 2

RAC48150532S1S1

Legend A1

Turn signal

H18

Pilot lamp for engine oil

S28

Vacuum switch for clogged hydraulic filter

A2

Electronics to secure travel

H19

Pilot lamp for engine coolant

S29

Cab fan selector switch

A3

Travel actuator

H20

Pilot lamp for diagnostics

S30

Front wiper switch

A4

Murphy display

K2-11

Auxiliary relays

S31

Rear wiper switch

A5

Fan drive control unit

K12

Starter contactor

S32

Washers double pushbutton

K13

Glowing contactor

S33

Heater fan selector switch

M1

Engine starter

S34

Auxiliary headlights switch

M2

Motor for cab lifting pump

S36

Switch to reduce drum slip

A6 B2 B3

Electronic control module (ECM) Hydraulic oil therometer sensor Hydraulic oil temperature sensor

B5

Fuel level

M3

Cab ventilation fan

S38

Coolant level indicator

B6

Engine speed control Hydraulics thermometer lighting

M4

Front wiper

S39

Diagnostic button

M5

Rear wiper

S40

ATC switch

Front fender lights

M6

Windshield washer

S41

Water in fuel indicator

V3

Interlocking LED (only with machines that have cab lifting alarm)

E1 E2,3

E4,5

Rear lamps

M7

Rear windshield washer

E6,7 E8,9

Front headlights Rear headlights

M8 M9

Heater fan Fuel pump

V2,4-7 Interlocking LEDs V8-11 Suppression diodes

E10,11 LH turn signals

P2

Hydraulic oil thermometer

X2-24

E12,13 RH turn signals

Q1

Battery disconnect

E14

Cab lighting

E15

Hazard beacon

R1.1, 1.4 Engine preheat R4,5

Resistor

X27

Interface connectors Socket for hazard beacon

X28-33 Interface connectors Socket for engine X34 diagnostics

License plate lamp

S2

Drop-out fuses

S3

Cab lifting double pushbutton Hood lifting double pushbutton Ignition box

F21-23 Drop-out fuses

S4

Front headlight switch

Y1

Cab lift solenoid valve

E16,17 Brake lights E18 F1-12

S1

X36-46 J1939 connector X64

Disgnostic socket

X50-53 Splitter connectors

G1,2

Batteries

S5

Rear headlight switch

Y2

Cab lowering solenoid valve

G3

Alternator

S6

Warning light switch

Y3

Hood lifting solenoid valve

S8

Turn signal light change over switch Hazard beacon switch

Y6

Hood lowering solenoid valve Brake solenoid valve Fast travel solenoid valve LH wheel Fast travel solenoid valve drum

H2

Pilot lamp for turn signal lights Horn

H3

Back-up alarm

S9

Horn switch

Y7

H4

Pilot lamp for hydraulic oil level

S11

Emergency brake pushbutton

Y8

H5

Pilot lamp for neutral

S14

Hydraulic oil level

Y9

Vibration 1 solenoid valve

H6

Pilot lamp for brake

S16

Fast travel switch

Y10

Vibration 2 solenoid valve

H7

Pilot lamp for vibration preset

S17

Selector switch for operating speed preset

Y11

Solenoid valve to disengage RTM module differential interlock

S18

Vibration selector switch

Y13

Servo valve for travel pump

S19

Vibration switch

Y14

Fast travel solenoid valve RH wheel

S21

Brake pressure switch

Y15

Fan drive proportional valve

S22

Seat switch Vacuum switch for clogged air filter

H1

H13

Pilot lamp for battery recharhing Pilot lamp for clogged air filter Pilot lamp for clogged hydraulic oil filter Fan drive error lamp

N17

Pilot lamp for glowing

H10 H11 H12

S7

S27

Y4

RAC48150532S1S2

Legend

6 500

MA A

13

210

210

L

T

20

L2

80/40-360

80/40-360

140

P

59

12 Vg max

Vg min

B M4

R

L1 MB

M5

7

MA A L2

15 16

P1

A

16 bar M

A

420

T

M4 P

P1

19

1,7 bar

8

M5

TRAVEL HYDROGENATOR

16

FLUSHING BLOCK

2

VIBRATION HYDROGENATOR

17

DIVIDER BLOCK

3

STEERING HYDROGENATOR

18

NOT USED

4

COOLING HYDROGENATOR

19

FILTER

5

NOT USED

20

ONE-WAY VALVE

6

DRUM TRAVEL HYDROMOTOR

21

FILLER NECK

7

RH WHEEL TRAVEL HYDROMOTOR

22

LEVEL INDICATOR

8

LH WHEEL TRAVEL HYDROMOTOR

23

COMBINED COOLER

9

VIBRATION HYDROMOTOR

24

NOT USED

10

COOLING HYDROMOTOR

25

THERMOMETER SENSOR

11

NOT USED

26

THERMOMETER SENSOR

12

STEERING HYDRAULIC CYLINDER

27

QUICK COUPLER FOR FILLING

13

POWER ASSISTED STEERING

28

QUICK COUPLER FOR MEASURING

14

NOT USED

29

QUICK COUPLER FOR MEASURING

15

BRAKE BLOCK

L1 MB

8

MA

C

420

1,4 bar

T

B

1

12

Vg min

1,2 mm

B

Vg max 15 bar

MA

B

B1 B2 B4 B3 B5

MB

28

17

Legend

A L2

S

28

Vg max B M4

12

Vg min M5

L1 MB

10 27

190 )(

11 )(

28

29

)(

R G1 G2 S

29

M1

23

4

25

8 2200 RPM

420

55 22

35

25

46

°C

9

1

M4

2

T1

28

M2

22 0,5 bar

SV208D T4B (Final)

3

M3

°C

26

420

T2

21

HYDRAULIC SCHEMATIC RAC 48150528

SUPPLY TRAVEL/VIBRATION (B) TRAVEL/VIBRATION (A) RETURN TO TANK

RAC48150528S1S1

Legend

6 500

MA A

13

210

210

L

T

20

L2

80/40-360

80/40-360

140

P

59

12 Vg max

Vg min

B M4

R

L1 MB

M5

7

MA A L2

15 16

P1

A

16 bar M

A

420

T

M4 P

P1

19

1,7 bar

8

M5

TRAVEL HYDROGENATOR

16

RTM CONTROL BLOCK

2

VIBRATION HYDROGENATOR

17

RTM MODULE

3

STEERING HYDROGENATOR

18

NOT USED

4

COOLING HYDROGENATOR

19

FILTER

5

NOT USED

20

ONE-WAY VALVE

6

DRUM TRAVEL HYDROMOTOR

21

FILLER NECK

7

RH WHEEL TRAVEL HYDROMOTOR

22

LEVEL INDICATOR

8

LH WHEEL TRAVEL HYDROMOTOR

23

COMBINED COOLER

9

VIBRATION HYDROMOTOR

24

NOT USED

10

COOLING HYDROMOTOR

25

THERMOMETER SENSOR

11

NOT USED

26

THERMOMETER SENSOR

12

STEERING HYDRAULIC CYLINDER

27

QUICK COUPLER FOR FILLING

13

POWER ASSISTED STEERING

28

QUICK COUPLER FOR MEASURING

14

NOT USED

29

QUICK COUPLER FOR MEASURING

15

BRAKE BLOCK

L1 MB

8

MA

C

420

1,4 bar

T

B

1

12

Vg min

1,2 mm

B

Vg max 15 bar

MA

B

B1 B2 B4 B3 B5

MB

28

17

Legend

A L2

S

28

Vg max B M4

12

Vg min M5

L1 MB

10 27

190 )(

11 )(

28

29

)(

R G1 G2 S

29

M1

23

4

25

8 2200 RPM

420

55 22

35

25

46

°C

9

1

M4

2

T1

28

M2

22 0,5 bar

SV208D T4B (Final)

3

M3

°C

26

420

T2

21

HYDRAULIC SCHEMATIC RAC 48150528

SUPPLY TRAVEL/VIBRATION (B) TRAVEL/VIBRATION (A) RETURN TO TANK

RAC48150528S1S2

40/22-320

Dn6

25/18-320

CAB LIFTING

25/18-320

BONNET LIFTING

A2

5

A2

Dn6

5

Dn6

Dn6

A2

6

6

6

X3

X3

X3

X2

X2

X2

A11

X1

X1

A1

X1

A11 A1

Dn6

4

A11 A1 T

Dn6

P

2

M

°C Dn6 °C

1

0,5 bar

Dn6

Dn6

B2 A2

80

0,5 kW M 1,9 24 V 60

B1 A1

50 Legend

3

100

Dn6

T P1

Dn6 Dn6

7

P

Dn10

1

HYDRAULIC TANK

2

LIFTING UNIT

3

LIFTING BLOCK

4

CAB LIFT HYDRAULIC CYLINDER

5

HOOD LIFT HYDRAULIC CYLINER

6

HYDRAULIC LOCK

SV208D T4B (Final) HYDRAULIC SCHEMATIC RAC 48150528

SUPPLY RETURN TO TANK

RAC48150528S2S1