Part number 47703709 2nd edition English September 2015 Replaces part number 84287236A SERVICE MANUAL DV210 Tier 3 Vibratory Roller
SERVICEMANUAL DV210 4770370909/09/2015
Contents INTRODUCTION Machinecompletionandequipment..............................................05 Engine.......................................................................................10 [10.001]Engineandcrankcase.............................................................10.1 [10.400]Enginecoolingsystem.............................................................10.2 Hydrostaticdrive.........................................................................29 [35.995]Compaction/vibrationhydraulicsystem............................................35.3 [35.500]Radiatorcleaningsystem..........................................................35.4 [35.304]Combinationpumpunits...........................................................35.5 Framesandballasting.................................................................39 Steering.....................................................................................41 [41.216]Cylinders...........................................................................41.3 Wheels......................................................................................44 Cabclimatecontrol.....................................................................50 [50.100]Heating.............................................................................50.1 4770370909/09/2015
[55.050]Heating,Ventilation,andAir-Conditioning(HVAC)controlsystem.................55.8 [55.512]Cabcontrols......................................................................55.10 Platform,cab,bodywork,anddecals.............................................90 [90.105]Machineshieldsandguards.......................................................90.2 4770370909/09/2015
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4770370909/09/2015
INTRODUCTION
4770370909/09/2015 1
INTRODUCTION
Contents
Safetyrules.....................................................................................4 Safetyrules.....................................................................................5 Safetyrules.....................................................................................7 Personalsafety...............................................................................14 Torque........................................................................................15 Specialtools..................................................................................18 Consumables.................................................................................22 Productidentification..........................................................................28 Productidentification..........................................................................29 4770370909/09/2015 2
Anyonewhoperformsrepairandmaintenanceoperationswithoutcomplyingwiththeproceduresprovidedherein
Themanufacturerreservestherighttomakeimprovementsindesignandchangesinspecificationsatanytimewithout illustrativematerialhereinareasaccurateasknownattimeofpublicationbutaresubjecttochangewithoutnotice.
INTRODUCTION Foreword-Importantnoticeregardingequipmentservicing
4770370909/09/2015 3
Safetyrules
Machinesafety
Information
NOTE:
Personalsafety
INTRODUCTION
ThroughoutthismanualyouwillfindthesignalwordsDANGER,WARNING,andCAUTIONfollowedbyspecialinFAILURETOFOLLOWDANGER,WARNING,ANDCAUTIONMESSAGESCOULDRESULT INDEATHORSERIOUSINJURY.
NOTICE: Noticeindicatesasituationthat,ifnotavoided,couldresultinmachineorpropertydamage. ThroughoutthismanualyouwillfindthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor propertydamage.ThewordNoticeisusedtoaddresspracticesnotrelatedtopersonalsafety.
4770370909/09/2015 4
INTRODUCTION Safetyrules Carefullyreadthesafetyrulescontainedhereinandfollowadvisedprecautionstoavoidpotentialhazardsandto Yoursafetyandthatofthepeoplearoundyoudependsonyou. Readthismanualcarefullyandcheckthat: • • Youunderstandfullythespeed,stability,brakingandsteeringcharacteristicsofthemachine.Ifyouareinany Thesafetymessagesinthissectionconcernsituationswhichmayariseduringnormalmachineoperation,servicing Theinformationgiveninthischapterisasummaryofthebasicrulestorespectatalltimesanddoesnotexemptyou suretheyarealwaysclean. Whenmountingordismountingfromthemachinealways facethemachineandusethestepsandaccesshandles LELI12TLB0048AB 1 Wearclosefittingclothingandsafetyequipment appropriateforthejob: • Safetyhelmet • Safetyshoes • Heavygloves • Reflectiveclothing • Wetweatherclothing followingpersonalsafetyequipmentshouldbeathand: • Respirators(ordustproofmasks) • Earplugsoracousticearsprotections • Goggleswithlateralshieldormasksforeyesprotection Donotwearrings,wristwatches,jewels,unbuttonedor jacketsorshirtswithopenzipswhichcouldgetcaughtinto LELI12TLB0049AB 2 4770370909/09/2015 5
INTRODUCTION Makesurethatyoufullyunderstandthesymbolsofthe safetydecalsappliedonthemachine.Makesurethat Bepreparedforemergencies. Alwayskeepafirstaidkitandafireextinguishercloseat dancewiththemanufacturer’sinstructions. LELI12TLB0050AB 3 4770370909/09/2015 6
INTRODUCTION Safetyrules Preventionoffireorexplosions Neverrefuelwhentheengineisrunning. Takeallthenecessarysafetymeasureswhenwelding, LELI12TLB0051AA 1 Asparkoraflamecancausetheelectrolyteofthebattery toexplode. instructions: • nectthenegative(-)cablefirst. • negative(-)cablelast. • • Donotweld,grindorsmokenearabattery. Beforeusingthemachineinanareawhichmaycontain tion. Makesurethatitisproperlymaintainedinconformitywith themanufacturer’sinstructions. LELI12TLB0052AA 2 4770370909/09/2015 7
INTRODUCTION Preventionofburns Thebatteryelectrolytegeneratessevereburns. Antidote: • • INTERNAL:Avoidvomiting.Drinkwatertorinseyour • EYES:Rinsethoroughlywithwaterfor 15min andget ifyouattempttochargethebatteryorifyoutrytostartthe Alwayskeepthebatterychargedtopreventtheelectrolyte LELI12TLB0053AA 3 Providegoodventilationwhenchangingabatteryorusing Thiscaninduceastateofelectrolysisandimpairthemain LELI12TLB0054AA 4 Hotcoolantcouldsprayoutiftheradiatorcapisremoved thecaptothefirstnotchandwaituntilthereisnomore pressure. LELI12TLB0055AA 5 4770370909/09/2015 8
INTRODUCTION Precautionsforwastedisposal isthereforeadvisabletopreparesuitablecontainersto collectandstoremomentarilyallsolidandfluidmaterials thatmustnotbescatteredintheenvironmenttoavoid Herebelowisalistoftheproductsinthemachinewhich requiredisposal: • Hydraulicoil • Brakesystemoil • freeze • Dieseloil • Oilanddieseloilfilterelements • • Battery Alsopollutingrags,paper,sawdustandglovesmustbe Donotusefoodorbeveragecontainersthatmaymislead theEarth’satmosphere. Obtaininformationontheproperwaytorecycleordispose LELI12TLB0056AA 6 4770370909/09/2015 9
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 4770370909/09/2015
Sealingcompounds
Spareparts
INTRODUCTION Safetyrules-Shopandassembly O-ringseals
• Machinemodel(commercialname)andProductIdentificationNumber(PIN) • 4770370909/09/2015 11
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 4770370909/09/2015
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 4770370909/09/2015
Personalsafety
INTRODUCTION
• • • • • 4770370909/09/2015
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 ( ) 4770370909/09/2015
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 4770370909/09/2015
