Case DV209D Service Manual
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Case DV209D Service Manual

Case DV209D Service Manual

Double drum compactor
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Double Drum Compactor
DV209D - PIN DDDD209DNGNTX2002 and above;
DV210D - PIN DDDD210DNGNTP2003 and above;
DV209CD Combi - PIN DDDD209CDNGNTG2001 and above;
DV210CD Combi - PIN DDDD210CDNGNTH2001 and above
SERVICE MANUAL
DV209D
DV210D
DV209CD Combi
DV210CD Combi
Tier 4B (final)
Part number 48123413
2
nd
Replaces part number 48032926
edition English
March 2017

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  • Page 1 DV210D DV209CD Combi DV210CD Combi Tier 4B (final) Double Drum Compactor DV209D - PIN DDDD209DNGNTX2002 and above; DV210D - PIN DDDD210DNGNTP2003 and above; DV209CD Combi - PIN DDDD209CDNGNTG2001 and above; DV210CD Combi - PIN DDDD210CDNGNTH2001 and above SERVICE MANUAL Part number 48123413...
  • Page 2 SERVICE MANUAL DV209CD Combi DV209CD Combi Asphalt Compactor - Tier 4B (final) [DDDD209CDNGNTG2001 - ] DV209D TIER 4B (FINAL) Double Drum Compactor [DDDD209DNGNTX2002 - ] DV210CD Combi DV210CD Combi Asphalt Compactor - Tier 4B (final) [DDDD210CDNGNTH2001 - ] DV210D TIER 4B (FINAL) Double Drum Compactor [DDDD210DNGNTP2003 - ] 48123413 29/03/2017 Find manuals at https://best-manuals.com...
  • Page 3 Contents INTRODUCTION Engine..................10 [10.001] Engine and crankcase ............. 10.1 [10.216] Fuel tanks .
  • Page 4 [55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system....55.2 [55.100] Harnesses and connectors............55.3 [55.301] Alternator .
  • Page 5 48123413 29/03/2017 Find manuals at https://best-manuals.com...
  • Page 6 INTRODUCTION 48123413 29/03/2017 Find manuals at https://best-manuals.com...

  • Page 7: Table Of Contents

    General specification - DV209D and DV209D HF (*) ....... . .

  • Page 8: Foreword - Important Notice Regarding Equipment Servicing

    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.

  • Page 9: Safety Rules

    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.

  • Page 10: Personal Safety

    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.
  • Page 11 INTRODUCTION Operate controls only when seated in the operator’s seat, except for those controls expressly intended for use from other locations. 48123413 29/03/2017...
  • Page 12 INTRODUCTION Before you leave the machine: 1. Park the machine on a firm, level surface. 2. Put all controls in neutral or park lock position. 3. Engage the parking brake. Use wheel chocks if required. 4. Lower all hydraulic equipment — Implements, header, etc. 5.
  • Page 13 INTRODUCTION Wheels and tires Make sure that tires are correctly inflated. Do not exceed any recommended load or pressure. Follow the instructions in the manual for proper tire inflation. Tires are heavy. Handling tires without proper equipment could cause death or serious injury. Always have a qualified tire technician service the tires and wheels.
  • Page 14 INTRODUCTION Do not expose the machine to flames, burning brush, or explosives. Promptly investigate any unusual smells or odors that may occur during operation of the machine. General battery safety Always wear eye protection when you work with batteries. Do not create sparks or have open flame near a battery. Ventilate the area when you charge a battery or use a battery in an enclosed area.
  • Page 15 INTRODUCTION Reflectors and warning lights You must use flashing amber warning lights when you operate equipment on public roads. Seat belts Seat belts must be worn at all times. Seat belt inspection and maintenance: • Keep seat belts in good condition. •...
  • Page 16 INTRODUCTION Operator protective structure Your machine is equipped with an operator protective structure, such as: a Roll Over Protective Structure (ROPS), Falling Objects Protective Structure (FOPS), or a cab with a ROPS. A ROPS may be a can frame or a two-posted or four-posted structure used for the protection of the operator to minimize the possibility of serious injury.
  • Page 17 INTRODUCTION Before you service your machine check the MSDS for each lubricant, fluid, etc. used in this machine. This information indicates the associated risks and will help you service the machine safely. Follow the information in the MSDS, and on manufacturer containers, as well as the information in this manual, when you service the machine. Dispose of all fluids, filters, and containers in an environmentally safe manner according to local laws and regulations.
  • Page 18 INTRODUCTION Working at heights When the normal use and maintenance of the machine requires you to work at heights: • Correctly use installed steps, ladders, and railings. • Never use ladders, steps, or railings while the machine is moving. • Do not stand on surfaces that are not designated as steps or platforms. Do not use the machine as a lift, ladder, or platform for working at heights.

  • Page 19: Safety Rules - Ecology And The Environment

    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.

  • Page 20: Torque - Minimum Tightening Torques For Normal Assembly

    INTRODUCTION Torque - Minimum tightening torques for normal assembly Double Drum DV METRIC NON-FLANGED HARDWARE NOM. LOCKNUT LOCKNUT SIZE CL.8 CL.10 CLASS 8.8 BOLT and CLASS 10.9 BOLT and W/CL8.8 W/CL10.9 CLASS 8 NUT CLASS 10 NUT BOLT BOLT PLATED PLATED UNPLATED UNPLATED...
  • Page 21 INTRODUCTION METRIC FLANGED HARDWARE NOM. CLASS 8.8 BOLT and CLASS 10.9 BOLT and LOCKNUT LOCKNUT SIZE CLASS 8 NUT CLASS 10 NUT CL.8 CL.10 W/CL8.8 W/CL10.9 BOLT BOLT PLATED PLATED UNPLATED UNPLATED W/ZnCr W/ZnCr 2.4 N·m (21 lb 3.2 N·m (28 lb 3.5 N·m (31 lb 4.6 N·m (41 lb 2.2 N·m (19 lb...
  • Page 22 INTRODUCTION 1. Manufacturer's Identification 2. Property Class 3. Clock Marking of Property Class and Manufacturer's Identification (Optional), i.e. marks 60° apart indicate Class 10 properties, and marks 120° apart indicate Class 8. INCH NON-FLANGED HARDWARE LOCKNUT LOCKNUT NOMINAL SAE GRADE 5 BOLT SAE GRADE 8 BOLT GrB W/ Gr5 GrC W/ Gr8...
  • Page 23 INTRODUCTION INCH FLANGED HARDWARE NOM- LOCKNUT LOCKNUT SAE GRADE 5 BOLT and SAE GRADE 8 BOLT and INAL GrF W/ Gr5 GrG W/ Gr8 SIZE BOLT BOLT UNPLATED PLATED UNPLATED PLATED or PLATED W/ZnCr or PLATED W/ZnCr SILVER GOLD SILVER GOLD 12 N·m (106 lb 13 N·m (115 lb...
  • Page 24 INTRODUCTION Inch Lock Nuts, All Metal (Three optional methods) 20090268 Grade Identification Grade Corner Marking Method (1) Flats Marking Method (2) Clock Marking Method (3) Grade A No Notches No Mark No Marks Grade B One Circumferential Notch Letter B Three Marks Grade C Two Circumferential Notches...

  • Page 25: Torque - Standard Torque Data For Hydraulic Connections

    Over-torquing of a hydraulic connection can also lead to leakage or failure. For some connections, CASE CONSTRUCTION requires a different torque value than is listed in the ISO and SAE standards. • The torque values in this document should be used whenever possible or applicable.
  • Page 26 INTRODUCTION Torque values for metric O-Ring Boss (ORB) port connections S-Series * L-Series ** Metric Ferrous Non-Ferrous Ferrous Non-Ferrous thread N·m (lb ft) ± 10% N·m (lb ft) ± 10% N·m (lb ft) ± 10% N·m (lb ft) ± 10% M8 x 1 10.5 (7.7) 6.3 (4.6)
  • Page 27 INTRODUCTION Torque values for port connections (British Standard Pipe Parallel (BSPP) thread ports and stud ends) Metric tube Outside Diameter (OD) Ferrous Non-Ferrous mm (in) BSPP S-Series L-Series S-Series L-Series thread S-Series * L-Series ** N·m (lb ft) N·m (lb ft) N·m (lb ft) N·m (lb ft) G- Gas;...
  • Page 28 INTRODUCTION Torque values for Inch O-Ring Boss (ORB) port non-adjustable connections S-Series * L-Series ** Ferrous Non- Ferrous Non- Inch tube UN/UNF N·m (lb ft) Ferrous N·m (lb ft) Ferrous dash size thread size ± 10% N·m (lb ft) ± 10% N·m (lb ft) mm (in) ±...
  • Page 29 INTRODUCTION Torque values for inch O-Ring Boss (ORB) port plugs Ferrous Non-Ferrous Internal hex External hex UN/UNF N·m (lb ft) N·m (lb ft) N·m (lb ft) dash size thread size ± 10% ± 10% ± 10% 5/16-24 7.5 (5.5) 12.5 (9.2) 7.5 (5.5) 3/8-24 14.5 (10.7)
  • Page 30 INTRODUCTION Torque values for four-bolt flange connections (Inch Screws, Grade 8) Code 61 Code 62 Metric size Imperial size Screw code Screw code N·m (lb ft) N·m (lb ft) ± 10% ± 10% 5/16-18 34 (25.1) 5/16-18 34 (25.1) 3/8-16 63 (46.5) 3/8-16 63 (46.5)
  • Page 31 INTRODUCTION Torque values for O-Ring Face Seals (ORFS) connections Hex size Metric Swivel nut Swivel nut Inch tube (mm) UN/UNF tube dash torque torque OD (mm) (Reference thread size OD (mm) size N·m (lb ft) N·m (lb ft) only) ± 10% ±...

  • Page 32: Basic Instructions - Shop And Assembly

    Only use CNH Original Parts or CASE CONSTRUCTION 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 or CASE CONSTRUCTION Original Parts can offer this guarantee.
  • Page 33 W0111A Special tools The special tools that CASE CONSTRUCTION suggests and illustrate in this manual have been specifically re- searched 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 oper- ation.

  • Page 34: Maintenance Chart

    INTRODUCTION Maintenance chart DV209CD Combi DV209D DV210CD Combi DV210D Change fluid Grease Drain fluid Replace Level make up Test Cleaning Bleed Check Adjust Maintenance action Every 10 hours or daily Engine oil level Engine coolant level Engines leaks Air filter dust valve...
  • Page 35 INTRODUCTION Change fluid Grease Drain fluid Replace Level make up Test Cleaning Bleed Check Adjust Maintenance action Water tank Water / Oil / Intercooler Radiator Engine Engine and machine control modules/control units Air-conditioning compressor drive belt (if equipped) Air-conditioning compressor mounting (if equipped) Every 2000 hours or 2 years Hydraulic oil and filter Engine coolant...

  • Page 36: Hydraulic Contamination

    INTRODUCTION Hydraulic contamination Double Drum DV 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 •...

  • Page 37: Capacities - Fluids, Lubricants And Capacities

    CASE AKCELA UNITEK 10W-40 Capacity 7.5 L (2 US gal) Two drum drive reducers on DV209D and DV209D HC and DV210D and DV210D HF One drum drive reducer and one axle drive reducer on DV209CD and DV210CD Combi Oil type...

  • Page 38: General Specification - Dv209D And Dv209D Hf

    INTRODUCTION General specification - DV209D and DV209D HF DV209D Weight DV209D DV209D HF Operating weight of CECE with cab, ROPS 9560 kg (21080 lb) Operating load of CECE with cab, ROPS on front axis 4770 kg (10520 lb) Operating load of CECE with cab, ROPS on rear axis...
  • Page 39 INTRODUCTION Vibration DV209D DV209D HF 42 Hz 46 Hz Frequency I (2520 Vib/Min) (2760 Vib/Min) 54 Hz 67 Hz Frequency II (3240 Vib/Min) (4020 Vib/Min) Amplitude I 0.7 mm (0.028 in) 0.62 mm (0.024 in) Amplitude II 0.34 mm (0.013 in) 0.23 mm (0.009 in)

  • Page 40: General Specification - Dv209Cd Combi

    INTRODUCTION General specification - DV209CD Combi DV209CD Combi Weight DV209CD Combi Operating weight of CECE with cab, ROPS 9410 kg (20750 lb) Operating load of CECE with cab, ROPS on front axis 4770 kg (10520 lb) Operating load of CECE with cab, ROPS on rear axis 4640 kg (10230 lb) Weight of half fluid capacities 540 kg (1190 lb)
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