CASE DV209B Tier 3 Double Drum Compactor Service Repair Manual Instant Download (PIN DDDD209BNGNT52033 and above)

DV209B Tier 3 Double Drum Compactor PIN DDDD209BNGNT52033 and above SERVICE MANUAL Printed in U.S.A. Part number 48038047 1st edition English 2016 CNH Industrial America LLC. All Rights Reserved. Case is a trademark registered in the United States and many other countries, owned by or licensed to CNH Industrial N.V., August 2016 its subsidiaries or affiliates.

SERVICE MANUAL DV209B TIER 3 Double Drum Compactor [DDDD209BNGNT52033 - ] 48038047 18/08/2016 EN

Contents INTRODUCTION Engine....................................................................................... 10 [10.001] Engine and crankcase ............................................................. 10.1 [10.216] Fuel tanks .......................................................................... 10.2 [10.400] Engine cooling system ............................................................. 10.3 Hydraulic systems....................................................................... 35 [35.000] Hydraulic systems.................................................................. 35.1 [35.300] Reservoir, cooler, and filters........................................................ 35.2 [35.353] Hydraulic travel system ............................................................ 35.3 [35.752] Hydraulic fan drive cooling 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 [50.100] Heating............................................................................. 50.1 Electrical systems....................................................................... 55 [55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system................. 55.1 [55.100] Harnesses and connectors......................................................... 55.2 48038047 18/08/2016

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[55.301] Alternator........................................................................... 55.3 [55.302] Battery.............................................................................. 55.4 [55.408] Warning indicators, alarms, and instruments ...................................... 55.5 [55.512] Cab controls........................................................................ 55.6 Platform, cab, bodywork, and decals............................................. 90 [90.151] Cab interior......................................................................... 90.1 [90.150] Cab................................................................................. 90.2 48038047 18/08/2016

INTRODUCTION 48038047 18/08/2016 1

INTRODUCTION Safety rules Double Drum DV 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 in- structions. 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. 48038047 18/08/2016 4

INTRODUCTION Personal safety Double Drum DV 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 pres- surize 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 ma- chine. 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. 48038047 18/08/2016 5

INTRODUCTION Product identification - Machine components Double Drum DV 1 RAIL14COM0271HC 48038047 18/08/2016 40

SERVICE MANUAL Engine DV209B TIER 3 Double Drum Compactor [DDDD209BNGNT52033 - ] 48038047 18/08/2016 10

Engine - Engine and crankcase Engine - General specification DV209B Engine type TCD 3.6 L4 Working principle Charging Type of cooling Cylinder arrangement No. of cylinders Bore/stroke Total displacement Combustion process Injection system Exhaust gas recirculation Exhaust gas aftertreatment Valves per cylinder Firing order of the engine Direction of rotation looking onto the flywheel Engine power rating according to ISO 3046 Speed (nominal revolutions) Injection timing Coolant volume Permissible continuous coolant temperature Temperature difference between coolant inlet/outlet Start of thermostat opening Thermostat fully open Lubricating oil change volume (with filter) Lube oil temperature in the lube oil tray, maximum Lubricating oil pressure minimum (low idle, engine warm) Permissible maximum combustion air temperature after charge air cooler Four-stroke diesel engine Turbocharger with charge air cooling water-cooled in series 4 98 mm (3.86 in) / 120 mm (4.72 in) 3621 cm (221 in ) Direct injection Common Rail externally cooled Diesel Oxidation Catalyst (DOC) 2 1-3-4-2 left See engine rating plate See engine rating plate See engine rating plate 4.6 L (1.22 US gal) max. 110 C (230 F) 8 C (15 F) 86 C (187 F) 102 C (216 F) 8 L (2.1 US gal) 125 C (257 F) 80 kPa (11.6 psi) 50 C (122 F) Pre-tensioning: 600 - 700 N (134.9 - 157.4 lb) Re-tensioning: 350 - 450 N (78.7 - 101.2 lb) Automatic tensioning spring-loaded clamping roller 350 kg (772 lb) V-belt tension: V-belts AVX (width: 13 mm) V-rib belt tensioning Weight without cooling system according to DIN 70020-A 48038047 18/08/2016 10.1 [10.001] / 3

Engine - Engine and crankcase Engine - Component identification DV209B Engine name plate (1) 1 RAIL14COM0213AA View from right 1. Crankcase breather 2. Throttle valve 3. Tension pulley 4. V-rib belt 5. Coolant inlet 6. Lubricating oil drain plug 7. Lube oil replacement filter 8. Lubricating oil dipstick 9. Coolant outlet 2 RAIL14COM0408AA View from left 1. Combustion air inlet 2. Exhaust outlet 3. Diesel particle filter 4. Diesel oxidation catalytic converter 5. Lubricating oil dipstick - Optional 6. Lube oil replacement filter - Optional 7. Lubricating oil filling 3 RAIL14COM0409AA 48038047 18/08/2016 10.1 [10.001] / 4

Engine - Engine and crankcase Electronic engine control 1. Rail pressure sensor 2. Charge air pressure transmitter, charge air tempera- ture transmitter 3. Coolant temperature transmitter 4. Engine control unit 5. Speed transmitter via camshaft 6. Speed transmitter via crankshaft 7. Fuel transducer 8. Lubricating oil pressure transmitter (on the opposite side) 4 RAIL14COM0410AA 9. Central plug (for engine control) 48038047 18/08/2016 10.1 [10.001] / 5

Engine - Fuel tanks Fuel tank - Exploded view Double Drum DV 1 RAIL14COM0805HA 48038047 18/08/2016 10.2 [10.216] / 3

Engine - Fuel tanks Description S. No 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Fuel tank Bolt Washer Bushing Filler cap Bracket Bolt Lock washer Washer Plug Fuel level sensor Washer Bolt Sleeve Shim 48038047 18/08/2016 10.2 [10.216] / 4

Engine - Fuel tanks Fuel tank - Remove Double Drum DV 1. Drain the fuel from the fuel tank using a suitable con- tainer that will hold 210 L (55.5 US gal). 2. Disconnect the wires (319) and (341) from the fuel level sensor (10). 1 RAIL14COM0736AA 3. Close the fuel shut-off valves (1). 4. Disconnect the hoses (2) and (3) from the fuel shut-off valves (1). 2 RAIL14COM0737AA 3 RAIL14COM0738AA 48038047 18/08/2016 10.2 [10.216] / 5

Engine - Fuel tanks 5. Remove the bolts, lock washers and washers (4) and brackets (5). 4 RAIL14COM0739AA 5 RAIL14COM0740AA 6. Remove the bolts and washers (6) and bushings, sleeves and shims (7). 6 RAIL14COM0741AA 7. Remove the fuel tank (8). NOTICE: Use suitable lifting equipment. Approx weight of the fuel tank: 40 kg (88 lb). 7 RAIL14COM0742AA 48038047 18/08/2016 10.2 [10.216] / 6

Engine - Fuel tanks 8. Remove the plug (9), fuel level sensor (10) and fuel shut-off valves (1) from the fuel tank (8). 8 RAIL14COM0743AA 9. Remove the sight gage (11) and fuel tank cap (12) from the fuel tank (8). 9 RAIL14COM0744AA 48038047 18/08/2016 10.2 [10.216] / 7

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Engine - Fuel tanks Fuel tank - Install Double Drum DV 1. Apply LOCTITE 577 on the contact surfaces of the sight gage (11) and fuel tank (8). 2. Install the sight gage (11) on the fuel tank (8). 3. Install the fuel tank cap (12) on the fuel tank (8). 1 RAIL14COM0744AA 4. Apply LOCTITE 577 on the contact surfaces of the plug (9), fuel level sensor (10) and fuel shut-off valves (1) and fuel tank (8). 5. Install the plug (9), fuel level sensor (10) and fuel shut- off valves (1) on the fuel tank (8). 2 RAIL14COM0743AA 6. Lift and place the fuel tank (8) in its correct position in the frame. NOTICE: Use suitable lifting equipment. Approx weight of the fuel tank: 40 kg (88 lb). 7. Secure the fuel tank (8) on the frame with the bolts and washers (6) and bushings, sleeves and shims (7). 3 RAIL14COM0741AA 48038047 18/08/2016 10.2 [10.216] / 8

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