Case DV210C Service Manual

DV209C
DV210C
Tier 4A
Vibratory Roller
SERVICE MANUAL
Printed in U.S.A.
Copyright © 2014 CNH Industrial America LLC. All Rights Reserved.
Case is a registered trademark of CNH Industrial America LLC.
Racine Wisconsin 53404 U.S.A.
Part number 47772910
1st edition English
December 2014
Contents
INTRODUCTION
Machine completion and equipment .............................................. 05
[05.102] Machine completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05.1
Engine....................................................................................... 10
[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
[10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
Hydrostatic drive......................................................................... 29
[29.218] Pump and motor components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.1
Hydraulic systems....................................................................... 35
[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1
[35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2
[35.752] Hydraulic fan drive cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3
[35.353] Hydraulic travel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4
[35.995] Compaction/vibration hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5
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
Wheels ...................................................................................... 44
[44.160] Compaction drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1
Cab climate control ..................................................................... 50
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[50.100] Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1
Electrical systems ....................................................................... 55
[55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1
[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2
[55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3
[55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4
[55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system. . . . . . . . . . . . . . . . . 55.5
[55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6
Platform, cab, bodywork, and decals ............................................. 90
[90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1
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INTRODUCTION
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Contents
INTRODUCTION
Foreword - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety rules - Ecology and the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Safety rules - Shop and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety rules – Hydraulic contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Hydraulic contamination – Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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INTRODUCTION
Foreword - Important notice regarding equipment servicing
All repair and maintenance work listed in this manual must be carried out only by qualified dealership personnel,
strictly complying with the instructions given, and using, whenever possible, the special tools.
Anyone who performs repair and maintenance operations without complying with the procedures provided herein
shall be responsible for any subsequent damages.
The manufacturer and all the organizations of its distribution chain, including - without limitation - national, regional, or
local dealers, reject any responsibility for damages caused by parts and/or components not approved by the manufacturer, including those used for the servicing or repair of the product manufactured or marketed by the manufacturer.
In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case
of damages caused by parts and/or components not approved by the manufacturer.
The manufacturer reserves the right to make improvements in design and changes in specifications at any time without
notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and
illustrative material herein are as accurate as known at time of publication but are subject to change without notice.
In case of questions, refer to your CASE CONSTRUCTION Sales and Service Networks.
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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
Safety rules
Carefully read the safety rules contained herein and follow advised precautions to avoid potential hazards and to
safeguard your safety and personal integrity.
Your safety and that of the people around you depends on you.
It is essential that you understand this manual for a correct inspection, lubrication and repair of this machine.
Read this manual carefully and check that:
• You understand fully the symbols on the controls and the safety signs used in this manual and on the machine.
• You understand fully the speed, stability, braking and steering characteristics of the machine. If you are in any
doubt, consult your Dealer.
The safety messages in this section concern situations which may arise during normal machine operation, servicing
and repair. These safety messages also indicate the different ways of coping with these situations. Other safety
messages are used throughout the manual to indicate specific dangers.
The information given in this chapter is a summary of the basic rules to respect at all times and does not exempt you
from observing traffic regulations or the requirements of insurance companies.
The presence of grease, oil, mud or (in winter) ice on the
steps and access handles can cause accidents. Make
sure they are always clean.
When mounting or dismounting from the machine always
face the machine and use the steps and access handles
on the left-hand side of the machine.
LELI12TLB0048AB
1
LELI12TLB0049AB
2
Wear close fitting clothing and safety equipment
appropriate for the job:
• Safety helmet
• Safety shoes
• Heavy gloves
• Reflective clothing
• Wet weather clothing
If the environment conditions make it necessary, the
following personal safety equipment should be at hand:
• Respirators (or dustproof masks)
• Ear plugs or acoustic ears protections
• Goggles with lateral shield or masks for eyes protection
Do not wear rings, wristwatches, jewels, unbuttoned or
flapping clothing such as ties, torn clothes, scarves, open
jackets or shirts with open zips which could get caught into
moving parts.
Any functional disorders, especially those affecting the
safety of the machine, should therefore be rectified immediately.
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INTRODUCTION
Make sure that you fully understand the symbols of the
safety decals applied on the machine. Make sure that
they are always clean and perfectly legible.
Be prepared for emergencies.
Always keep a first aid kit and a fire extinguisher close at
hand on the machine.
Make sure that the fire extinguisher is serviced in accordance with the manufacturer’s instructions.
LELI12TLB0050AB
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INTRODUCTION
Safety rules
Prevention of fire or explosions
The engine fuel can originate an explosion or a fire.
Never refuel when the engine is running.
Do not smoke during refuelling.
Take all the necessary safety measures when welding,
grinding or when working near a naked flame.
Use a non-inflammable product for cleaning parts.
LELI12TLB0051AA
1
LELI12TLB0052AA
2
A spark or a flame can cause the electrolyte of the battery
to explode.
To prevent any risk of explosion, observe the following
instructions:
• When disconnecting the battery cables, always disconnect the negative (-) cable first.
• To reconnect the battery cables, always connect the
negative (-) cable last.
• Never short-circuit the battery clamps with metal objects.
• Do not weld, grind or smoke near a battery.
The engine exhaust may produce sparks.
Before using the machine in an area which may contain
inflammable vapours, ensure that there is good ventilation.
Always keep a fire extinguisher available on the machine.
Make sure that it is properly maintained in conformity with
the manufacturer’s instructions.
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INTRODUCTION
Prevention of burns
The battery electrolyte generates severe burns.
The battery contains sulphuric acid.
Avoid any contact with the skin, eyes or clothing.
Antidote:
• EXTERNAL: Rinse well with water, removing any soiled
clothing.
• INTERNAL: Avoid vomiting. Drink water to rinse your
mouth. Consult a doctor.
• EYES: Rinse thoroughly with water for 15 min and get
prompt medical attention.
LELI12TLB0053AA
3
LELI12TLB0054AA
4
LELI12TLB0055AA
5
When the electrolyte of a battery is frozen, it can explode
if you attempt to charge the battery or if you try to start the
engine using a booster battery.
Always keep the battery charged to prevent the electrolyte
freezing.
Batteries generate explosive gases.
Keep all flames, sparks and cigarettes away.
Provide good ventilation when changing a battery or using
a battery in an enclosed space.
Always protect your eyes when working near a battery.
Never touch the battery terminals with your hands.
This can induce a state of electrolysis and impair the main
organs of the body.
Hot coolant could spray out if the radiator cap is removed
while the system is still hot.
To remove the cap: Allow the system to cool down, turn
the cap to the first notch and wait until there is no more
pressure.
Then remove the cap.
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INTRODUCTION
Precautions for waste disposal
Improperly disposing of waste can threaten the environment.
Each country has its own Regulations on this subject. It
is therefore advisable to prepare suitable containers to
collect and store momentarily all solid and fluid materials
that must not be scattered in the environment to avoid
pollution.
At preset intervals these products will be delivered to disposal stations legally recognized and present in this Country.
Here below is a list of the products in the machine which
require disposal:
LELI12TLB0056AA
• Hydraulic oil
• Brake system oil
• Coolant mixture, condensation residue and pure antifreeze
• Diesel oil
• Oil and diesel oil filter elements
• Engine and air-conditioning air filter elements
• Battery
Also polluting rags, paper, sawdust and gloves must be
disposed in compliance with the same procedures.
Do not use food or beverage containers that may mislead
someone into drinking from them.
Do not pour waste onto the ground, down a drain, or into
any water source.
Air-conditioning coolant escaping into the air can damage
the Earth’s atmosphere.
Government regulations may require a certified air-conditioning service centre to recover and recycle used air-conditioning coolant.
Obtain information on the proper way to recycle or dispose
of waste from your local environmental or recycling centre,
or from your Dealer.
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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 - Shop and assembly
O-ring seals
Lubricate the O-ring seals before you insert them in the seats. This will prevent the O-ring seals from overturning and
twisting, which would jeopardize sealing efficiency.
Sealing compounds
Apply a sealing compound on the mating surfaces when specified by the procedure. Before you apply the sealing
compound, prepare the surfaces as directed by the product container.
Spare parts
Only use CNH Original Parts.
Only genuine spare parts guarantee the same quality, duration, and safety as original parts, as they are the same
parts that are assembled during standard production. Only CNH Original Parts can offer this guarantee.
When ordering spare parts, always provide the following information:
• Machine model (commercial name) and Product Identification Number (PIN)
• Part number of the ordered part, which can be found in the parts catalog
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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
Safety rules – Hydraulic contamination
Contamination in the hydraulic system is a major cause of the malfunction of hydraulic components. Contamination
is any foreign material in the hydraulic oil.
Contamination can enter the hydraulic system in several ways:
• When you drain the oil or disconnect any line
• When you disassemble a component
• From normal wear of the hydraulic components
• From damaged seals or worn seals
• From a damaged component in the hydraulic system
All hydraulic systems operate with some contamination. The design of the components in this hydraulic system permits efficient operation with a small amount of contamination. An increase in this amount of contamination can cause
problems in the hydraulic system.
The following list includes some of these problems:
• Cylinder rod seals that leak
• Hydraulic oil that becomes too hot
• Pump gears, housing, and other parts that wear rapidly
• Relief valves or check valves held open by dirt
• Quick failure of components that have been repaired
• The machine does not have enough power.
If your machine has any of these problems, check the hydraulic oil for contamination.
There are two types of contamination: microscopic and visible.
Microscopic contamination occurs when very fine particles of foreign material are suspended in the hydraulic oil.
These particles are too small to see or feel. Microscopic contamination can be found by identification of the following
problems or by testing in a laboratory.
Examples of problems caused by microscopic contamination:
• Cylinder rod seals that leak
• The hydraulic system has a high operating temperature
Visible contamination is foreign material that can be found by sight, touch, or odor. Visible contamination can cause
a sudden failure of components.
Examples of problems caused by visible contamination:
• Particles of metal or dirt in the oil
• Air in the oil
• Dark or thick oil
• Oil with an odor of burned oil
• Water in the oil
If you find contamination, use a portable filter to clean the hydraulic system.
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INTRODUCTION
Personal safety
Wear Personal Protective Equipment (PPE) such as hard hat, eye protection, heavy gloves, hearing protection, protective clothing, etc.
Wear working footwear with non-slip soles. Smooth soles may slip from steps and pedals resulting in injury or incorrect
operation.
Wear closely fitting work clothes when operating the machine. Loose, wide garments may result in the control lever
being inadvertently activated.
Keep clear of moving parts. Loose clothing, jewelry, watches, long hair, and other loose or hanging items can become
entangled in moving parts.
Do not smoke or use an open flame when at work.
Always wear eye protection when working with batteries.
Do not create sparks or have an open flame near the battery.
Hydraulic oil or diesel fuel leaking under pressure can penetrate the skin, causing serious injury or infection.
• Do not use your hand to check for leaks. Use a piece of cardboard or paper.
• Stop engine, remove key and relieve the pressure before connecting or disconnecting fluid lines.
• Make sure all components are in good condition and tighten all connections before starting the engine or pressurizing the system.
• If hydraulic fluid or diesel penetrates the skin, seek medical attention immediately.
• Continuous long term contact with hydraulic fluid may cause skin cancer. Avoid long term contact and wash the
skin promptly with soap and water.
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INTRODUCTION
Torque
• Confirm regularly that bolted connections have not come loose.
• Use torque wrenches for tightening.
• If a special torque is needed, it is mentioned in the section.
Thread size
M6
M8
M8x1
M10
M10x1.25
M12
M12x1.25
M14
M14x1.5
M16
M16x1.5
M18
M18x1.5
M20
M20x1.5
M22
M22x1.5
M24
M24x2
M27
M27x2
M30
M30x2
TIGHTENING TORQUE
For screws
8.8 (8G)
10 N·m (7.4 lb ft)
24 N·m (17.7 lb ft)
19 N·m (14.0 lb ft)
48 N·m (35.4 lb ft)
38 N·m (28.0 lb ft)
83 N·m (61.2 lb ft)
66 N·m (48.7 lb ft)
132 N·m (97.4 lb ft)
106 N·m (78.2 lb ft)
200 N·m (147.5 lb ft)
160 N·m (118.0 lb ft)
275 N·m (202.8 lb ft)
220 N·m (162.3 lb ft)
390 N·m (287.6 lb ft)
312 N·m (230.1 lb ft)
530 N·m (390.9 lb ft)
425 N·m (313.5 lb ft)
675 N·m (497.9 lb ft)
540 N·m (398.3 lb ft)
995 N·m (733.9 lb ft)
795 N·m (586.4 lb ft)
1350 N·m (995.7 lb ft)
1080 N·m (796.6 lb ft)
For srews
10.9 (10K)
14 N·m (10.3 lb ft)
34 N·m (25.1 lb ft)
27 N·m (19.9 lb ft)
67 N·m (49.4 lb ft)
54 N·m (39.8 lb ft)
117 N·m (86.3 lb ft)
94 N·m (69.3 lb ft)
185 N·m (136.4 lb ft)
148 N·m (109.2 lb ft)
285 N·m (210.2 lb ft)
228 N·m (168.2 lb ft)
390 N·m (287.6 lb ft)
312 N·m (230.1 lb ft)
550 N·m (405.6 lb ft)
440 N·m (324.5 lb ft)
745 N·m (549.5 lb ft)
590 N·m (435.2 lb ft)
950 N·m (700.7 lb ft)
760 N·m (560.5 lb ft)
1400 N·m (1032.6 lb ft)
1120 N·m (826.0 lb ft)
1900 N·m (1401.4 lb ft)
1520 N·m (1121.1 lb ft)
The values given in the table are torques at dry thread (at coefficient of friction = 0.14). These values do not apply to
greased thread.
Table with torques of cap nuts with O-ring - hoses
Size wrench
Thread size
Hose
14
12x1.5
6
17
14x1.5
8
19
16x1.5
22
18x1.5
24
20x1.5
12
27
22x1.5
14
15
30
24x1.5
16
32
26x1.5
18
8
10
10
12
Tightening torques for cap nuts with O-ring - hoses
Nominal
Min
Max
20 N·m (14.8 lb
15 N·m (11.1 lb
25 N·m (18.4 lb
ft)
ft)
ft)
38 N·m (28.0 lb
30 N·m (22.1 lb
45 N·m (33.2 lb
ft)
ft)
ft)
45 N·m (33.2 lb
38 N·m (28.0 lb
52 N·m (38.4 lb
ft)
ft)
ft)
51 N·m (37.6 lb
43 N·m (31.7 lb
58 N·m (42.8 lb
ft)
ft)
ft)
58 N·m (42.8 lb
50 N·m (36.9 lb
65 N·m (47.9 lb
ft)
ft)
ft)
74 N·m (54.6 lb
60 N·m (44.3 lb
88 N·m (64.9 lb
ft)
ft)
ft)
74 N·m (54.6 lb
60 N·m (44.3 lb
88 N·m (64.9 lb
ft)
ft)
ft)
105 N·m (77.4 lb 85 N·m (62.7 lb 125 N·m (92.2 lb
ft)
ft)
ft)
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INTRODUCTION
Size wrench
Thread size
36
30x2
41
46
36x2
50
42x2
30
45x2
35
52x2
38
42
50
Tightening torques for cap nuts with O-ring - hoses
Nominal
Min
Max
135 N·m (99.6 lb 115 N·m (84.8 lb 155 N·m (114.3 lb
ft)
ft)
ft)
166 N·m (122.4 lb 140 N·m (103.3 lb 192 N·m (141.6 lb
ft)
ft)
ft)
240 N·m (177.0 lb 210 N·m (154.9 lb 270 N·m (199.1 lb
ft)
ft)
ft)
290 N·m (213.9 lb 255 N·m (188.1 lb 325 N·m (239.7 lb
ft)
ft)
ft)
330 N·m (243.4 lb 280 N·m (206.5 lb 380 N·m (280.3 lb
ft)
ft)
ft)
Hose
20
22
25
28
Table for torques of necks with sealing edge
or with flat gasket
G-M
G 1/8
G1/4
G 3/8
G 1/2
G 3/4
G1
G 11/4
G 11/2
Tightening torques for flanges
25 N·m (18 lb ft)
40 N·m (30 lb ft)
95 N·m (70 lb ft)
130 N·m (96 lb ft)
250 N·m (184 lb ft)
400 N·m (295 lb ft)
600 N·m (443 lb ft)
800 N·m (590 lb ft)
10 x 1
12 x 1.5
14 x 1.5
16 x 1.5
18 x 1.5
20 x 1.5
22 x 1.5
26 x 1.5
27 x 1.5
33 x 1.5
42 x 1.5
48 x 1.5
25 N·m (18 lb ft)
30 N·m (22 lb ft)
50 N·m (37 lb ft)
60 N·m (44 lb ft)
60 N·m (44 lb ft)
140 N·m (103 lb ft)
140 N·m (103 lb ft)
220 N·m (162 lb ft)
250 N·m (184 lb ft)
400 N·m (295 lb ft)
600 N·m (443 lb ft)
800 N·m (590 lb ft)
SS12C493
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1
INTRODUCTION
Table for torques of plugs with flat gasket
G-M
G 1/8
G1/4
G 3/8
G 1/2
G 3/4
G1
G 11/4
G 11/2
Tightening torques for flanges
15 N·m (11 lb ft)
33 N·m (24 lb ft)
70 N·m (52 lb ft)
90 N·m (66 lb ft)
150 N·m (111 lb ft)
220 N·m (162 lb ft)
600 N·m (443 lb ft)
800 N·m (590 lb ft)
10 x 1
12 x 1.5
14 x 1.5
16 x 1.5
18 x 1.5
20 x 1.5
22 x 1.5
26 x 1.5
27 x 1.5
33 x 1.5
42 x 1.5
48 x 1.5
13 N·m (10 lb ft)
30 N·m (22 lb ft)
40 N·m (30 lb ft)
60 N·m (44 lb ft)
70 N·m (52 lb ft)
90 N·m (66 lb ft)
100 N·m (74 lb ft)
120 N·m (89 lb ft)
150 N·m (111 lb ft)
250 N·m (184 lb ft)
400 N·m (295 lb ft)
500 N·m (369 lb ft)
SS12K194
2
SS12N446
3
Hydraulic cylinder for steering 80/45–320
(2) Piston rod, (3) Piston,
(4) Nut
Thread
M30x2
Tightening
torque
130 N·m
(96 lb ft)
(1) Hydraulic cylinder
body, (5) Hydraulic
cylinder cover
Thread
Tightening
torque
M85x1.5
180 N·m
(133 lb ft)
Hydraulic cylinder for CRAB 110/55–125
(2) Piston rod, (3) Piston,
(4) Nut
Thread
M42x3
Tightening
torque
180 N·m
(133 lb ft)
(1) Hydraulic cylinder
body, (5) Hydraulic
cylinder cover
Thread
Tightening
torque
M115x2
220 N·m
(162 lb ft)
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INTRODUCTION
Hydraulic contamination – Contamination
Contamination in the hydraulic system is a major cause of the malfunction of hydraulic components. Contamination
is any foreign material in the hydraulic oil. Contamination can enter the hydraulic system in several ways.
1. When you drain the oil or disconnect any line.
2. When you disassemble a component.
3. From normal wear of the hydraulic components.
4. From damaged or worn seals.
5. From a damaged component in the hydraulic system.
All hydraulic systems operate with some contamination. The design of the components in this hydraulic system
permits efficient operation with a small amount of contamination. An increase in this amount of contamination can
cause problems in the hydraulic system. The following list includes some of these problems.
1. Cylinder rod seals leak.
2. Control valve spools do not return to neutral.
3. Movement of control valve spools is difficult.
4. Hydraulic oil becomes too hot.
5. Pump gears, housing, and other parts wear rapidly.
6. Relief valves or check valves held open by dirt.
7. Quick failure of components that have been repaired.
8. Cycle times are slow; machine does not have enough power.
If your machine has any of these problems, check the hydraulic oil for contamination. See types of contamination
below. If you find contamination, use the Portable Filter to clean the hydraulic system.
NOTE: There are two types of contamination, microscopic and visible.
Microscopic contamination occurs when very fine particles of foreign material are in suspension in the hydraulic oil.
These particles are too small to see or feel. Microscopic contamination can be found by identification of the following
problems or by testing in a laboratory. Examples of the problems:
1. Cylinder rod seal leak.
2. Control valve spools do not return to NEUTRAL.
3. The hydraulic system has a high operating temperature.
Visible contamination is foreign material that can be found by sight, touch, or odor. Visible contamination can cause
a sudden failure of components. Examples of visible contamination:
1. Particles of metal or dirt in the oil.
2. Air in the oil.
3. The oil is dark and thick.
4. The oil has an odor of burned oil.
5. Water in the oil.
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INTRODUCTION
Consumables
CASE CONINTERNATIONAL
STRUCRECOMMENDED FLUIDS
Specifications
TIONSpecifiAND APPLICATION
cations
CASE
SAE 10W40
AKCELA
ENGINE - OIL
API CJ-4
UNITEK
ACEA E9
10W-40
COOLING SYSTEM
CNH XHD
CNH XHD HEAVY DUTY
HEAVY DUTY ASTM D6210 Type
COOLANT / ANTI-FREEZE
COOLANT /
1-FF
ANTI-FREEZE
antifreeze 50% water 50%
CASE
DIN 51524 PART 3
AKCELA
API GL-4
NEXHYDRAULIC SYSTEM
ISO VG-32/46
PLORE™
SAE 10W30
FLUID
FUEL TANK
Ultra Low Sulfur Diesel
(ULSD)
SAE ASTM EN590
Decanted and filtered diesel
ASTM D975 S15
fuel (Sulfur not exceeding
15 mg/kg)
TUTELA
STEERING JOINT
MULTI BEARINGS, YOKE
PURPOSE
NLGI 2
BEARINGS, STEERING
EP GREASE
SWIVEL PINS,
251H, GR-9
SUSPENSIONS:
CASE
SAE 10W40
AKCELA
VIBRATION DRUM
API CJ-4
UNITEK
ACEA E9
10W-40
TUTELA
HYPOIDE
EP GEAR
LUBE SAE
80W-90
API GL-5
or
DRUM DRIVE REDUCER
MIL-L-2105 D
TUTELA
HYPOIDE
EP GEAR
LUBE SAE
85W-140
–
water
GLASS WASHER TANK
SPRINKLING TANK
Water
–
MODELS
QUANTITY
ALL
9 L (2.38 US gal)
ALL
23 L (6.08 US gal)
ALL
60 L (15.85 US gal)
ALL
210 L (55.48 US gal)
ALL
As required
ALL
2 X 10.5 L (2.77 US
gal)
ALL
2 x 2 L (0.53 US gal)
ALL
2.75 L (0.73 US gal)
840 L (221.90 US
gal)
2 X 100 L (26.42 US
gal)
ALL
ALL
DRUM COOLING LIQUID
AIR-CONDITIONING
SYSTEM
-
—
ALL
AIR-CONDITIONING
COMPRESSOR
CNH PAG
OIL or PAG
SP20
–
ALL
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0.3 L (0.08 US gal)
INTRODUCTION
Engine oil
Engine oil has been specified as per its performance classification and viscosity classification.
Performance classification under:
American Petroleum Institute (API)
Viscosity classification
The ambient temperature and type of operations at the place where the machine will be used are decisive in determining Society of Automotive Engineers (SAE) viscosity class.
• Exceeding the low temperature limit will not cause engine damage; but may cause some starting difficulties.
• It is convenient to use universal multi-range oils to avoid the need to change oil due to ambient temperature.
• It is possible to use a synthetic engine oil if the performance and viscosity classifications of the oil correspond to
the recommended mineral oils.
• The oil change intervals used must be the same as those for mineral oils.
• To make starting at temperatures below 0 °C (32 °F) easier, the engine manufacturer recommends SAE 10W-30
oil.
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INTRODUCTION
NOTICE: Do not allow the upper temperature limit to be
exceeded for long periods of time as this will reduce the
capabilities of the oil.
When using oil API CG-4/SH, the oil change interval must
be reduced by half, i.e. 125 h.
Viscosity diagram
SS12C358
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1
INTRODUCTION
Fuel
WARNING
Fire hazard!
Do not add gasoline, alcohol, or blended fuels to diesel fuel, except as recommended in this manual.
Fuel combinations may increase fire and explosion hazards.
Failure to comply could result in death or serious injury.
W0401A
Use fuel that complies with the American Society for Testing and Materials (ASTM) D975 standard:
Grade no. 2 fuel
Fuel viscosity must be over 1.3 centi Stokes (cSt) at 40 °C (104 °F) to ensure proper liquidity characteristics and
proper lubrication of fuel system components.
NOTICE: Check with your fuel supplier for the correct cold weather fuel.
Coolant
WARNING
Chemical hazard!
Follow the instructions on the container when handling anti-freeze.
Failure to comply could result in death or serious injury.
W1109A
Use antifreeze in all seasons to protect the cooling system from corrosion and all risk of freezing.
For areas where ambient temperature is over -36 °C (-32.8 °F), use a blend of 50 % ethylene-gylcol based antifreeze.
For areas where the temperature is below -36 °C (-32.8 °F), it is advisable to use a blend of 40 % water and 60 %
antifreeze.
NOTICE: Do not use coolant with an antifreeze concentration greater than 50 %. Point of congelation is -36 °C (-33 °F)
and the boiling point is 110 °C (230 °F), unless absolutely required.
Never use an antifreeze concentration over 68 %!
We do not recommend the blending of antifreeze agents. Blending various types of coolant may cause loss of anticorrosion properties.
Always check the antifreeze concentration of the coolant with a refractometer before the winter season starts.
Hydraulic oil
Only hydraulic oil CASE AKCELA HY-TRAN® ULTRA™ HYDRAULIC TRANSMISSION OIL may be used for the
machine’s hydraulic system.
Fill the machine with hydraulic oil of cinematic viscosity 68 mm² per second at 40 °C (104 °F), i.e. ISO VG 68. This
oil is most appropriate for use within the widest range of ambient temperatures.
Synthetic hydraulic oil
It is possible to fill the hydraulic system with synthetic oil for which any leakage will be completely biodegraded via
microorganisms found in water and soil.
NOTICE: Always consult with the oil manufacturer or dealer before switching from mineral oil to synthetic oil or mixing
oils of various brands!
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INTRODUCTION
Transmission fluid
Use high-quality oil corresponding to API GL-5, or EP or MIL-L-2105 D to lubricate gearbox, pumps and drum reductors.
Use TUTELA HYPOIDE SSL SYNTHETIC GEAR LUBE SAE 75W-90 fluid for outdoor temperature range -10 - 30 °C (14 86 °F).
or use TUTELA HYPOIDE SSL SYNTHETIC GEAR LUBE SAE 80W-140 fluid for outdoor temperature range 20 - 45 °C (68
- 113 °F).
NOTICE: Operating temperature of oil should never exceed 85 - 90 °C (185 - 194 °F).
Brake fluid
The fluid should comply with international specifications DOT3. It is mixable with brake fluids of all brands that comply
with these specifications. Brake fluid is designed for brake systems that operate at ambient temperatures from -50 °C
(-58 °F) to 60 °C (140 °F) and at operating temperatures from -50 °C (-58 °F) to 205 °C (401 °F).
NOTICE: Brake fluid that corresponds to the international classification DOT 4 may also be used for the brake system.
Lube grease
Use plastic lubricant with lithium content to lubricate the machine:
Case Akcela Extreme pressure grease moly
To lubricate the speed reduction transmission, use the lubricant according to:
ISO 6743/9 BDHB2
Washer fluid
Use clean water at a temperature of no lower than 0 °C (32 °F) when filling the washer fluid reservoir. We recommend
the use of washer fluid with antifreeze for motor vehicle windshield washers at the ratio necessitated by machine
lubricating conditions.
NOTICE: When there is a risk that temperatures will drop below 0 °C (32 °F), add antifreeze agent or drain the water!
Drum cooling liquid
Use antifreeze in all seasons to protect the cooling system from corrosion and all risk of freezing.
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INTRODUCTION
Product identification
When ordering parts, requesting information or assistance, always give your Dealer the model and Product Identification Number (PIN) of your machine and component concerned.
Machine
Product identification plate provides the following
information:
1. Type / Model
2. Product Identification Number (PIN)
RAIL14COM0213AA
1
RAIL14COM0348BA
2
RAIL14COM0259AA
3
Machines PIN can also be located on the front frame as
indicated (1).
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INTRODUCTION
Engine
Engine identification plate (1) is located below the Machine identification plate
RAIL14COM0213AA
4
RAIL14COM0260AA
5
Roll Over Protective Structure (ROPS)
ROPS identification plate (1) is located on the protective
structure inside the cab
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INTRODUCTION
Product identification
RAIL14COM0271HC
1
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