Part number 48142070 1st edition English September 2017 Replaces part number 47538933 SERVICE MANUAL DV36 DV45 Tier 4A (interim) Vibratory Roller DV45CC Tier 4A (interim) Combination Roller
SERVICEMANUAL DV36 DV45CC DV45 4814207015/09/2017
Contents INTRODUCTION Maintenance..............................................................................00 [00.150]Start-up.............................................................................00.1 Engine.......................................................................................10 Hydrostaticdrive.........................................................................29 [29.218]Pumpandmotorcomponents......................................................29.1 Brakesandcontrols....................................................................33 Hydraulicsystems.......................................................................35 [35.104]Fixeddisplacementpump..........................................................35.1 [35.000]Hydraulicsystems..................................................................35.2 [35.102]Pumpcontrolvalves................................................................35.3 [35.300]Reservoir,cooler,andfilters........................................................35.5 [35.995]Compaction/vibrationhydraulicsystem............................................35.6 Framesandballasting.................................................................39 Steering.....................................................................................41 Wheels......................................................................................44 4814207015/09/2017
Tools.........................................................................................89 [89.165]Waterkit............................................................................89.1 Platform,cab,bodywork,anddecals.............................................90 4814207015/09/2017
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4814207015/09/2017
4814207015/09/2017 1
INTRODUCTION
Contents
Safetyrules.....................................................................................3 Personalsafety.................................................................................8 Torque........................................................................................10 Specialtools..................................................................................13 Capacities.....................................................................................21 Consumables.................................................................................22 4814207015/09/2017 2
INTRODUCTION
Personalsafety
INTRODUCTION
Safetyrules
ThroughoutthismanualyouwillfindthesignalwordsDANGER,WARNING,andCAUTIONfollowedbyspecialinFAILURETOFOLLOWDANGER,WARNING,ANDCAUTIONMESSAGESCOULDRESULT INDEATHORSERIOUSINJURY. Machinesafety NOTICE: Noticeindicatesasituationthat,ifnotavoided,couldresultinmachineorpropertydamage. ThroughoutthismanualyouwillfindthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor propertydamage.ThewordNoticeisusedtoaddresspracticesnotrelatedtopersonalsafety. Information NOTE: 4814207015/09/2017 3
INTRODUCTION Safetyrules-Ecologyandtheenvironment Whenlegislationdoesnotyetrulethetreatmentofsomeofthesubstancesrequiredbyadvancedtechnology,sound NOTE: Thefollowingarerecommendationsthatmaybeofassistance: • Becomeacquaintedwithandensurethatyouunderstandtherelativelegislationapplicabletoyourcountry. • Helpfulhints • Avoidfillingtanksusingcansorinappropriatepressurizedfueldeliverysystemsthatmaycauseconsiderable • • Modernoilscontainadditives.Donotburncontaminatedfuelsandorwasteoilsinordinaryheatingsystems. • • • • Donotincreasethepressureinapressurizedcircuitasthismayleadtoacomponentfailure. • oils,coolant,etc. 4814207015/09/2017 4
INTRODUCTION Safetyrules-Shopandassembly O-ringseals Sealingcompounds
• Machinemodel(commercialname)andProductIdentificationNumber(PIN)
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Spareparts
•
INTRODUCTION Protectingtheelectronicand/orelectricalsystemsduringchargingandwelding Toavoiddamagetotheelectronicand/orelectricalsystems,alwaysobservethefollowingpractices: • • • weld. NOTICE: Ifyoumustweldontheunit,youmustdisconnectthebatterygroundcablefromthemachinebattery. Specialtools WARNING Batteryacidcausesburns.Batteriescontainsulfuricacid. Avoidcontactwithskin,eyesorclothing.Antidote(external):Flushwithwater.Antidote(eyes):flush quantitiesofwaterormilk.Donotinducevomiting.Seekmedicalattentionimmediately. W0111A repairoperations.Thespecialtoolsareaccuratelybuiltandrigorouslytestedtoofferefficientandlong-lastingoperation. • Operatinginoptimaltechnicalconditions • Obtainingthebestresults • Savingtimeandeffort • Workinginsafeconditions 4814207015/09/2017 6
Contaminationcanenterthehydraulicsysteminseveralways:
• Whenyoudraintheoilordisconnectanyline
• Whenyoudisassembleacomponent
• Fromnormalwearofthehydrauliccomponents
• Fromdamagedsealsorwornseals
• Fromadamagedcomponentinthehydraulicsystem
•
•
INTRODUCTION Safetyrules-Hydrauliccontamination Contaminationinthehydraulicsystemisamajorcauseofthemalfunctionofhydrauliccomponents.Contamination
Allhydraulicsystemsoperatewithsomecontamination.Thedesignofthecomponentsinthishydraulicsystemper-
Thefollowinglistincludessomeoftheseproblems:
Cylinderrodsealsthatleak
Hydraulicoilthatbecomestoohot
Reliefvalvesorcheckvalvesheldopenbydirt
• •
• Quickfailureofcomponentsthathavebeenrepaired
Theseparticlesaretoosmalltoseeorfeel.Microscopiccontaminationcanbefoundbyidentificationofthefollowing
• Themachinedoesnothaveenoughpower.
Examplesofproblemscausedbymicroscopiccontamination:
• Cylinderrodsealsthatleak
Particlesofmetalordirtintheoil
Airintheoil
Darkorthickoil
Oilwithanodorofburnedoil
Waterintheoil 4814207015/09/2017 7
• Thehydraulicsystemhasahighoperatingtemperature Examplesofproblemscausedbyvisiblecontamination: •
•
•
•
•
Personalsafety
INTRODUCTION
• • • • • 4814207015/09/2017 8
INTRODUCTION Basicinstructions-Importantnoticeregardingequipmentservicing Anyonewhoperformsrepairandmaintenanceoperationswithoutcomplyingwiththeproceduresprovidedherein type,orchangestothelawsandregulationsofdifferentcountries. 4814207015/09/2017 9
INTRODUCTION Torque NOTICE: Thescrewscanloosenduetothevibrationoftheroller! Unlessotherwisespecified,secureallscrewswith L OCTITE ®242® . Thevaluesbelowapply: • Unlessotherwisespecifiedinthemanual • Tofemalesteelthreads Hexagonscrews/boltsandhexagon-socket-headcapscrews AFsizehexagonAFsizehexagon socket ScrewdiameterSteelquality Tighteningtorque 7 3 8.8 ( 2.2lbft ) 8 4 6N·m ( 4.4lbft ) 5 M6 10N·m ( ) 6 M8 ( 18.4lbft ) 6 M8 36N·m ( 26.6lbft ) - 90N·m ( 66.4lbft ) 8 M10 48N·m ( ) M12 8.8 ( 62.0lbft ) M12 123N·m ( 90.7lbft ) - 246N·m ( ) M14 133N·m ( ) M16 8.8 ( 151.9lbft ) - M16 302N·m ( 222.7lbft ) - M20 415N·m ( ) - M20 ( 436.6lbft ) Extremelylow-profilecheese-headscrews Allenkeysize Screwdiameter Steelquality Tighteningtorque 3 M5 3N·m ( ) 3 M6 10.9 ( 4.4lbft ) 4 M8 13N·m ( 9.6lbft ) 5 M10 25N·m ( ) Flangedoval-headscrews Allenkeysize Screwdiameter Steelquality Tighteningtorque M4 ( 1.8lbft ) 3 M5 5N·m ( ) 4 M6 10.9 ( 5.9lbft ) 5 M8 12N·m ( 8.9lbft ) Countersunkheadscrews Allenkeysize Screwdiameter Steelquality Tighteningtorque 3 M5 ( 2.8lbft ) 4 M6 ( 4.9lbft ) 5 M8 16N·m ( ) Shoulderscrews Allenkeysize Screwdiameter Steelquality Tighteningtorque 6 M10 43N·m ( ) 4814207015/09/2017
INTRODUCTION Operatorseat,seatbeltfasteningscrews AFsizehexagonkey Screwdiameter Steelquality Tighteningtorque 5/8“ UNF7/16” 45N·m ( ) Draincock Draincock Dieseltank Securethescrewconnectionswith L OCTITE ®565™PST andtightenbyhand,not Hydraulictank Securethescrewconnectionswith L OCTITE ®565™PST ThreadedboltforROPSjoint Screwdiameter Steelquality Tighteningtorque M18 S355 ( 108.4lbft )( 30kg ( 66lb ) 50cm ( 20in )lever) Greasewith L OCTITE ®A NTI EIZE lubricatingcompound,forexample. Threadedadapters/Metricthreads Threadsize Cuttingring Softseatring Nominaljointsize 18N·m ( ) 18N·m ( ) 6 L M12x1.5 ( 18.4lbft ) ( 18.4lbft ) 8 L 45N·m ( 33.2lbft ) 45N·m ( 33.2lbft ) L 55N·m ( ) 55N·m ( ) L ( 51.6lbft ) ( 51.6lbft ) L 125N·m ( 92.2lbft ) 125N·m ( 92.2lbft ) L 180N·m ( 132.8lbft ) 180N·m ( 132.8lbft ) L 310N·m ( ) 310N·m ( ) L M12x1.5 ( 25.8lbft ) ( 29.5lbft ) 6 S 55N·m ( 40.6lbft ) 40N·m ( 29.5lbft ) 8 S 70N·m ( ) 70N·m ( ) S 110N·m ( ) 90N·m ( ) S M20x1.5 ( 110.6lbft ) ( 92.2lbft ) S 170N·m ( 125.4lbft ) 135N·m ( 99.6lbft ) S 270N·m ( )
( ) S Threadedadapters/Inchthreads Threadsize Cuttingring Softseatring Nominaljointsize 1/8“ 18N·m ( 13.3lbft ) 18N·m ( 13.3lbft ) 6 L 1/4“ 25N·m ( ) 25N·m ( ) 8 L 1/4“ ( 33.2lbft ) ( 33.2lbft ) L 3/8“ 55N·m ( 40.6lbft ) 55N·m ( 40.6lbft ) L 1/2“ 70N·m ( ) 70N·m ( ) L 1/2“ 125N·m ( ) 125N·m ( ) L 3/8“ ( 132.8lbft ) ( 132.8lbft ) L 310N·m ( 228.6lbft ) 310N·m ( 228.6lbft ) L 1/4“ 35N·m ( ) 40N·m ( ) 6 S 1/4“ ( 40.6lbft ) ( 29.5lbft ) 8 S 3/8“ ( 51.6lbft ) ( 51.6lbft ) S 3/8“ 110N·m ( 81.1lbft ) 90N·m ( 66.4lbft ) S 1/2“ 150N·m ( ) 125N·m ( ) S 1/2“ ( 125.4lbft ) ( 99.6lbft ) S 3/4“ 270N·m ( 199.1lbft ) 180N·m ( 132.8lbft ) S 4814207015/09/2017 11
180N·m
NOTE: Totightenhydraulichosesandfittings: 90° ) 4814207015/09/2017
INTRODUCTION
Specialtools
bearingflangeclampring
SVIL13SPT0583AB 1 ring
SVIL13SPT0584AB 2 Assemblytoolforpendulumjoint
SVIL13SPT0585AB 3 Assemblytoolforvibroshaft (1) M12eyeboltnotincludedinscopeofdelivery
SVIL13SPT0586AB 4 4814207015/09/2017
INTRODUCTION
SVIL13SPT0590AB 5 Assemblytool,press-insleeveforvibrobearing
SVIL13SPT0595AB 6 Assemblytoolforsteeringcylinder
SVIL13SPT0591AB 7 Assemblytoolfordrivebearing
SVIL13SPT0596AB 8 4814207015/09/2017
INTRODUCTION
Assemblytool,supportsleeveforvibrobearing(indrive bearingflange)
SVIL13SPT0597AB 9 Assemblytoolforpinionfastener
SVIL13SPT0598AB
SVIL13SPT0601AB 11 withM16eyebolt
SVIL13SPT0600AB
INTRODUCTION Assemblytoolforshaftsealingring
4814207015/09/2017
SVIL13SPT0602AB
Assemblytoolforvibroshaft
SVIL13SPT0603AB Pullertoolforpendulumsupportbolts
SVIL13SPT0604AB Specialwrenchforrearwheelsupportfasteningbolts
SVIL13SPT0605AB 4814207015/09/2017
INTRODUCTION Assemblytool,pressureplatefordrivebearingflange withM16bolt
