Part number 47703681 2nd edition English September 2015 Replaces part number 84287260A SERVICE MANUAL PT240 Tier 3 Pneumatic Line Roller
SERVICEMANUAL PT240 4770368109/09/2015
Contents INTRODUCTION Engine.......................................................................................10 [10.414]Fananddrive......................................................................10.1 [10.400]Enginecoolingsystem.............................................................10.2 [10.001]Engineandcrankcase.............................................................10.3 Transmission..............................................................................21 Frontaxlesystem.......................................................................25 Rearaxlesystem........................................................................27 [33.300]Pneumaticservicebrakes..........................................................33.1 [33.110]Parkingbrakeorparkinglock......................................................33.2 Hydraulicsystems.......................................................................35 [35.000]Hydraulicsystems..................................................................35.1 Pneumaticsystem......................................................................36 Framesandballasting.................................................................39 [39.500]Vibratoryroller......................................................................39.1 Steering.....................................................................................41 4770368109/09/2015
Wheels......................................................................................44 [44.511]Frontwheels........................................................................44.1 [44.520]Rearwheels........................................................................44.2 Cabclimatecontrol.....................................................................50 Electricalsystems.......................................................................55 Tools.........................................................................................89 [89.165]Waterkit............................................................................89.1 Platform,cab,bodywork,anddecals.............................................90 4770368109/09/2015
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4770368109/09/2015
INTRODUCTION
4770368109/09/2015 1
INTRODUCTION
Contents
Safetyrules.....................................................................................4 Personalsafety...............................................................................10 Torque........................................................................................11 Specialtools..................................................................................18 Generalspecification.........................................................................25 Generalspecification.........................................................................31 Productidentification(*)......................................................................36 Partidentification(*)..........................................................................37 Productidentification(*)......................................................................38 4770368109/09/2015 2
Anyonewhoperformsrepairandmaintenanceoperationswithoutcomplyingwiththeproceduresprovidedherein
Themanufacturerreservestherighttomakeimprovementsindesignandchangesinspecificationsatanytimewithout illustrativematerialhereinareasaccurateasknownattimeofpublicationbutaresubjecttochangewithoutnotice.
INTRODUCTION Foreword-Importantnoticeregardingequipmentservicing
4770368109/09/2015 3
Safetyrules
Machinesafety
Information
NOTE:
Personalsafety
INTRODUCTION
ThroughoutthismanualyouwillfindthesignalwordsDANGER,WARNING,andCAUTIONfollowedbyspecialinFAILURETOFOLLOWDANGER,WARNING,ANDCAUTIONMESSAGESCOULDRESULT INDEATHORSERIOUSINJURY.
NOTICE: Noticeindicatesasituationthat,ifnotavoided,couldresultinmachineorpropertydamage. ThroughoutthismanualyouwillfindthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor propertydamage.ThewordNoticeisusedtoaddresspracticesnotrelatedtopersonalsafety.
4770368109/09/2015 4
INTRODUCTION Safetyrules-Personalsafety Carefullystudytheseprecautions,andthoseincludedintheexternalattachmentoperators manual,andinsistthattheybefollowedbythoseworkingwithandforyou. 1.ThoroughlyreadandunderstandthismanualandtheattachmentOperator’sManualbeforeoperatingthisorany 2.Besureallpeopleandpetsareclearofthemachinebeforestarting.Soundthehorn,ifequipped,threetimes 4.Keepallshieldsinplace.Neverworkaroundthemachineoranyoftheattachmentswhilewearinglooseclothing 5.Observethefollowingprecautionswheneverlubricatingthemachineormakingadjustments. • • Lowertheattachment,ifequipped,tothegroundorraisetheattachmentcompletelyandengagethecylinder • Engagetheparkingbrake. • • 10.Iftheattachmentormachineshouldbecomeobstructedorplugged;settheparkingbrake,shutofftheengine 13.Whentransportingonaroadorhighway,useaccessorylightsanddevicesforadequatewarningtotheoperatorsofothervehicles.Inthisregard,checklocalgovernmentregulations.Varioussafetylightsanddevicesare andattachment. 19.Extremecareshouldbetakeninkeepinghandsandclothingawayfrommovingparts. 4770368109/09/2015 5
INTRODUCTION Safetyrules-Ecologyandtheenvironment Soil,air,andwaterqualityisimportantforallindustriesandlifeingeneral.Whenlegislationdoesnotyetrulethe legislation.Wherenolegislationexists,obtaininformationfromsuppliersofoils,filters,batteries,fuels,anti-freeze, cleaningagents,etc.,withregardtotheeffectofthesesubstancesonmanandnatureandhowtosafelystore,use, Helpfulhints • • • • etc.Donotmixdrainedbrakefluidsorfuelswithlubricants.Storealldrainedfluidssafelyuntilyoucandisposeof • Donotallowcoolantmixturestogetintothesoil.Collectanddisposeofcoolantmixturesproperly. • • • • Batteryrecycling Batteriesandelectricaccumulatorscontainseveralsubstancesthatcanhaveaharmful CONSTRUCTIONstronglyrecommendsthatyoureturnallusedbatteriestoaCASE batteriesproperly.Insomecountries,thisisalegalrequirement. Mandatorybatteryrecycling NOTE: Batteriesaremadeofleadplatesandasulfuricacidsolution.Becausebatteriescontainheavymetalssuchaslead, CONAMAResolution401/2008requiresyoutoreturnallusedbatteriestothebatterydealerwhenyoureplaceany Pointsofsaleareobligedto: • Acceptthereturnofyourusedbatteries • Storethereturnedbatteriesinasuitablelocation • Sendthereturnedbatteriestothebatterymanufacturerforrecycling 4770368109/09/2015 6
Sealingcompounds
Spareparts
INTRODUCTION Safetyrules-Shopandassembly O-ringseals
• Machinemodel(commercialname)andProductIdentificationNumber(PIN) • 4770368109/09/2015 7
INTRODUCTION Protectingtheelectronicand/orelectricalsystemsduringchargingandwelding Toavoiddamagetotheelectronicand/orelectricalsystems,alwaysobservethefollowingpractices: • • • weld. NOTICE: Ifyoumustweldontheunit,youmustdisconnectthebatterygroundcablefromthemachinebattery. WARNING Avoidcontactwithskin,eyesorclothing.Antidote(external):Flushwithwater.Antidote(eyes):flush withwaterfor15minutesandseekmedicalattentionimmediately.Antidote(internal):Drinklarge Failuretocomplycouldresultindeathorseriousinjury. W0111A Specialtools repairoperations.Thespecialtoolsareaccuratelybuiltandrigorouslytestedtoofferefficientandlong-lastingoperation. • Operatinginoptimaltechnicalconditions • Obtainingthebestresults • Savingtimeandeffort • Workinginsafeconditions 4770368109/09/2015 8
Contaminationcanenterthehydraulicsysteminseveralways:
• Whenyoudraintheoilordisconnectanyline
• Whenyoudisassembleacomponent
• Fromnormalwearofthehydrauliccomponents
• Fromdamagedsealsorwornseals
• Fromadamagedcomponentinthehydraulicsystem
Thefollowinglistincludessomeoftheseproblems:
• Cylinderrodsealsthatleak
• Hydraulicoilthatbecomestoohot
•
• Reliefvalvesorcheckvalvesheldopenbydirt
• Quickfailureofcomponentsthathavebeenrepaired
• Themachinedoesnothaveenoughpower.
Examplesofproblemscausedbymicroscopiccontamination:
• Cylinderrodsealsthatleak
• Thehydraulicsystemhasahighoperatingtemperature Examplesofproblemscausedbyvisiblecontamination:
•
•
•
•
•
INTRODUCTION Safetyrules–Hydrauliccontamination Contaminationinthehydraulicsystemisamajorcauseofthemalfunctionofhydrauliccomponents.Contamination
Allhydraulicsystemsoperatewithsomecontamination.Thedesignofthecomponentsinthishydraulicsystemper-
Theseparticlesaretoosmalltoseeorfeel.Microscopiccontaminationcanbefoundbyidentificationofthefollowing
Particlesofmetalordirtintheoil
Airintheoil
Darkorthickoil
Oilwithanodorofburnedoil
Waterintheoil 4770368109/09/2015 9
Personalsafety
INTRODUCTION
• • • • • 4770368109/09/2015
10N·m
7.4lbft ) 14N·m ( 10.3lbft ) 24N·m ( 17.7lbft ) 34N·m ( 25.1lbft )
27N·m
M8x1 19N·m
M10 ( 35.4lbft ) ( 49.4lbft ) 38N·m ( 28.0lbft ) 54N·m ( 39.8lbft )
M12 83N·m (
66N·m (
117N·m (
94N·m (
M14 ( 97.4lbft ) ( 136.4lbft ) 106N·m ( 78.2lbft ) 148N·m ( 109.2lbft )
M16 200N·m
285N·m (
160N·m ( 118.0lbft ) 228N·m ( 168.2lbft )
M18 ( 202.8lbft ) ( 287.6lbft ) 220N·m ( 162.3lbft ) 312N·m ( 230.1lbft )
M20 390N·m ( ) 550N·m ( ) ( 230.1lbft ) ( 324.5lbft )
M22 530N·m ( 390.9lbft ) 745N·m ( 549.5lbft ) 425N·m ( 313.5lbft ) 590N·m ( 435.2lbft )
M24 675N·m ( ) 950N·m ( ) M24x2 ( 398.3lbft ) ( 560.5lbft )
M27 995N·m ( 733.9lbft ) 1400N·m ( 1032.6lbft ) M27x2 795N·m ( ) 1120N·m ( )
M30 1350N·m ( ) 1900N·m ( ) M30x2 ( 796.6lbft )
1121.1lbft )
INTRODUCTION Torque • • • ThreadsizeTIGHTENINGTORQUE Forscrews 8.8(8G) Forsrews 10.9(10K)
(
( )
( )
)
)
)
)
( )
)
(
TighteningtorquesforcapnutswithO-ring-hoses Sizewrench ThreadsizeHoseNominal Min Max 6 20N·m ( 14.8lb ) 15N·m ( 11.1lb ) 25N·m ( 18.4lb ) 8 38N·m ( 28.0lb ) 30N·m ( 22.1lb ) 45N·m ( 33.2lb ) 8 45N·m ( 33.2lb ) 38N·m ( 28.0lb ) 52N·m ( 38.4lb ) ( 37.6lb ) ( 31.7lb ) ( 42.8lb ) ( 42.8lb ) ( 36.9lb ) ( 47.9lb ) 22x1.5 ( 54.6lb ) ( 44.3lb ) ( 64.9lb ) 74N·m ( ) 60N·m ( ) 88N·m ( ) 105N·m ( ) 85N·m ( ) 125N·m ( ) 4770368109/09/2015 11
G11/4
18lbft
30lbft
70lbft
96lbft )
184lbft )
295lbft )
443lbft )
590lbft )
10x1 25N·m ( 18lbft )
( 22lbft )
( 37lbft )
( 44lbft )
( 44lbft )
( 103lbft )
( 103lbft )
( 162lbft )
( 184lbft )
( 295lbft ) ( 443lbft )
( 590lbft )
INTRODUCTION Sizewrench ThreadsizeHoseNominal Min Max 30x2 135N·m ( ) 115N·m ( ) 155N·m ( ) 36x2 166N·m ( ) 140N·m ( ) 192N·m ( ) 42x2 240N·m ( 177.0lb ) 210N·m ( 154.9lb ) 270N·m ( 199.1lb ) 45x2 290N·m ( 213.9lb ) 255N·m ( 188.1lb ) 325N·m ( 239.7lb ) 52x2 330N·m ( 243.4lb ) 280N·m ( 206.5lb ) 380N·m ( 280.3lb ) Tablefortorquesofneckswithsealingedge orwithflatgasket G-MTighteningtorquesforflanges G1/8 25N·m (
) G1/4 (
) G3/8 95N·m (
) G1/2 130N·m (
G3/4 250N·m (
G1 (
600N·m (
G11/2 800N·m (
30N·m
50N·m
16x1.5
60N·m
140N·m
140N·m
26x1.5
250N·m
400N·m
800N·m
SS12C493 1 4770368109/09/2015
G1/8 15N·m ( 11lbft )
G1/4 33N·m ( 24lbft )
G3/8 ( 52lbft )
G1/2 90N·m ( 66lbft )
G3/4 150N·m ( 111lbft )
G1 220N·m ( 162lbft )
G11/4 ( 443lbft )
G11/2 800N·m ( 590lbft )
10x1 ( 10lbft )
12x1.5 ( 22lbft )
40N·m ( 30lbft )
60N·m ( 44lbft ) ( 52lbft )
90N·m ( 66lbft )
100N·m ( 74lbft )
120N·m ( 89lbft )
27x1.5 ( 111lbft )
250N·m ( 184lbft ) 400N·m ( 295lbft ) 500N·m ( 369lbft )
INTRODUCTION Tablefortorquesofplugswithflatgasket
SS12K194 2 4770368109/09/2015
INTRODUCTION Torque-Standardtorquedataforhydraulics INSTALLATIONOFADJUSTABLEFITTINGS INSTRAIGHTTHREADORINGBOSSES tothemetalbackupwasherwhichisassembledatthe extremeendofthegroove (4) . themetalbackupwashercontactsthefaceoftheboss (5) NOTE: Donotovertightenanddistortthemetal fittingwithawrench,tightenthelocknutandwasher againstthefaceoftheboss (6) 23085659 1 STANDARDTORQUEDATAFORHYDRAULICTUBESANDFITTINGS TUBENUTSFOR37°FLAREDFITTINGS O-RINGBOSSPLUGS ADJUSTABLEFITTING LOCKNUTS,SWIVEL SIZETUBINGOD THREAD SIZE TORQUE TORQUE 4 6.4mm ( 1/4in ( ) ( ) 5 7.9mm ( 5/16in ( 12-15lbft ) ( 10-15lbft ) 6 9.5mm ( 3/8in )9/16-18 ( 21-24lbft ) ( 15-20lbft ) 8 ( 1/2in ( 35-40lbft ) ( 25-30lbft ) 15.9mm ( 5/8in ( ) ( ) 19.1mm ( 3/4in ( 77-82lbft ) ( 60-70lbft ) 22.2mm ( 7/8in )1-3/16-12 ( 90-100lbft ) ( 70-80lbft ) ( 1in ( 110-120lbft ) ( 80-90lbft ) 31.8mm ( ( ) ( ) 38.1mm ( 1-1/2in ( 160-175lbft ) ( 120-140lbft ) ( 2in ( 225-240lbft ) ( 250-300lbft ) Thesetorquesarenotrecommendedfortubesof 12.7mm ( 1/2in )ODandlargerwithwallthicknessof 0.889mm ( ( Beforeinstallingandtorquing 37° cleanerandapplyhydraulicsealant L OCTITE®569 tothe37° 4770368109/09/2015
FACED)FITTINGS
INTRODUCTION PIPETHREADFITTINGTORQUE threadswithacleansolventorLoctitecleanerandapply sealant L OCTITE ®567PSTP IPE S EALANT forallfittings includingstainlesssteelor L OCTITE ®565PSTformost temsuse L OCTITE®545 PIPETHREADFITTING ThreadSize Torque(Maximum) 1/8-27 13N·m ( 10lbft ) 16N·m ( 12lbft ) ( 16lbft ) 41N·m ( 30lbft ) 54N·m ( 40lbft ) INSTALLATIONOFORFS(O-RINGFLAT
WheninstallingORFSfittingsthoroughlycleanbothflat surfacesofthefittings (1) (2) with Torquethefittingtospecifiedtorquelistedthroughoutthe repairmanual. NOTICE: Ifthefittingsurfacesarenotproperlycleaned, NOTICE: Alwaysusegenuinefactoryreplacementoils gineandhydraulicsystemoils. systemcleanwillextendmachineandcomponentlife. 50011183 2 4770368109/09/2015
INTRODUCTION Basicinstructions-Shopandassembly Shimming Rotatingshaftseals NOTE: andthedustlipondoublelipsealswithgrease. O-ringseals Sealingcompounds compound,preparethesurfacesasdirectedbytheproductcontainer. Spareparts OnlyuseCNHOriginalPartsorCASECONSTRUCTIONOriginalParts. partsthatareassembledduringstandardproduction.OnlyCNHOriginalPartsorCASECONSTRUCTIONOriginal Whenorderingspareparts,alwaysprovidethefollowinginformation: • Machinemodel(commercialname)andProductIdentificationNumber(PIN) • 4770368109/09/2015
