Vibratory Rollers

Single Drum

Service Manual

604.13.235
 NOTE: CASE Company reserves the right to make changes in the specification and design of the machine
without prior notice and without incurring any obligation to modify units previously sold.

The description of the models shown in this manual has been made in accordance with the technical spec-
ifications known as of the date of design of this document.

Copyright  2002 Case France

Printed in France
604.13.235 09 - 2002
 CONTENTS

SECTION 00 - MAINTENANCE
Chapter 1 - General Instructions
Description Page
Introduction ........................................................................................................................................................ 1
Safety instructions.............................................................................................................................................. 3
Environmental measures and health precautions.............................................................................................. 6
Product identification.......................................................................................................................................... 8
Torque specifications ......................................................................................................................................... 9

SECTION 00 - MAINTENANCE
Chapter 2 - General Specifications
Description Page
Description of the machine ................................................................................................................................ 1
Fluids and lubricants .......................................................................................................................................... 2
Specifications..................................................................................................................................................... 5
Overall machine dimensions............................................................................................................................ 10

SECTION 00 - MAINTENANCE
Chapter 3 - Troubleshooting
Description Page
Troubleshooting - Engine................................................................................................................................... 2
Troubleshooting - Hydraulic system oil overheating - emulsifying ..................................................................... 3
Troubleshooting - Vibration................................................................................................................................ 3
Troubleshooting - Travel .................................................................................................................................... 5
Troubleshooting - Brakes................................................................................................................................... 6
Troubleshooting - Steering................................................................................................................................. 6

SECTION 00 - MAINTENANCE
Chapter 4 - Special service tools
Description Page
Tools and equipment ......................................................................................................................................... 1

604.13.235 - 09/2002 C7 - C9 - C11 - C15

2 CONTENTS

SECTION 10 - ENGINE
Chapter 1 - Removal and installation
Description Page
Specifications..................................................................................................................................................... 1
Description ......................................................................................................................................................... 2
Torque specifications ......................................................................................................................................... 4
Special tools....................................................................................................................................................... 4
Removal............................................................................................................................................................. 6
Installation........................................................................................................................................................ 13
Accelerator cable assembly removal and installation ...................................................................................... 13

SECTION 21 - TRANSMISSION
Chapter 1 - Hydraulic motor
Description Page
Description ......................................................................................................................................................... 2
Specifications..................................................................................................................................................... 3
Torque specifications ......................................................................................................................................... 3
Disassembly....................................................................................................................................................... 3
Reconditioning and replacement ....................................................................................................................... 5
Assembly ........................................................................................................................................................... 8

SECTION 21 - TRANSMISSION
Chapter 2 - Travel reduction gear
Description Page
Specification....................................................................................................................................................... 1
Torque specifications ......................................................................................................................................... 2
Special tools....................................................................................................................................................... 2
Exploded view of travel brake ............................................................................................................................ 6
Disassembly and assembly ............................................................................................................................... 7
Brake test........................................................................................................................................................... 9
Exploded view.................................................................................................................................................. 10
Disassembly and assembly ............................................................................................................................. 11

SECTION 29 - HYDROSTATIC DRIVE

Chapter 1 - Pumps - Cento drive coupling
Description Page
Specifications..................................................................................................................................................... 1
Torque specifications ......................................................................................................................................... 1
Description ......................................................................................................................................................... 2
Special tools....................................................................................................................................................... 3
Removal of pumps, Drive coupling .................................................................................................................... 3
Drive coupling .................................................................................................................................................... 7

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 CONTENTS 3

SECTION 35 - HYDRAULIC SYSTEM

Chapter 1 - Hydraulic cylinders for Cab and Hood
Description Page
Torque Specifications ........................................................................................................................................ 1
Description ......................................................................................................................................................... 2
Special tools....................................................................................................................................................... 3
Hood hydraulic cylinders.................................................................................................................................... 5
Cab hydraulic cylinder........................................................................................................................................ 7
Hydraulic cylinders............................................................................................................................................. 7

SECTION 35 - HYDRAULIC SYSTEM

Chapter 2 - Vibration Motor
Description Page
Specifications..................................................................................................................................................... 1
Torque specifications ......................................................................................................................................... 1
Description ......................................................................................................................................................... 2
Disassembly....................................................................................................................................................... 3
Assembly ........................................................................................................................................................... 8
Supply pressure relief valve adjustment .......................................................................................................... 12

SECTION 35 - HYDRAULIC SYSTEM

Chapter 3 - Hydraulic circuit
Description Page
Hydraulic installation .......................................................................................................................................... 2
Functional description ........................................................................................................................................ 2
Travel without activation .................................................................................................................................... 3
Travel activated, moving forward ....................................................................................................................... 4
The multi-function valve ..................................................................................................................................... 5
The idler-wheel lock-block on the flow divider ................................................................................................... 6
ASC valve .......................................................................................................................................................... 7
Vibration hydraulics............................................................................................................................................ 8
Vibration without activation ................................................................................................................................ 8
Vibration activated ........................................................................................................................................... 10
Steering hydraulics .......................................................................................................................................... 12
Steering without activation ............................................................................................................................... 13
Steering to the right.......................................................................................................................................... 14
Lifting hydraulics .............................................................................................................................................. 15
Lifting of the cab or hood ................................................................................................................................. 16
Lowering the cab and hood.............................................................................................................................. 17
Reservoir hydraulics ........................................................................................................................................ 18
Hydraulic reservoir ........................................................................................................................................... 18
Discharging of closed circuits .......................................................................................................................... 19
Brake release - emergency towing .................................................................................................................. 20
Test points ....................................................................................................................................................... 21
Releasing transmission and wheel hydraulic motor brakes ............................................................................. 23
Hydraulic diagram ............................................................................................................................................ 26
C7 - C9 - C11 - C15 604.13.235 - 09/2002
4 CONTENTS

SECTION 35 - HYDRAULIC SYSTEM

Chapter 4 - Hydraulic pump
Description Page
Specifications..................................................................................................................................................... 1
Torque specifications ......................................................................................................................................... 1
Description ......................................................................................................................................................... 2
Disassembly....................................................................................................................................................... 3
Reconditioning and replacement of parts .......................................................................................................... 8
Assembly ......................................................................................................................................................... 14
Inspection and adjustments ............................................................................................................................. 26

SECTION 39 - FRAMES
Chapter 1 - Drum
Description Page
Description ......................................................................................................................................................... 2
Specifications..................................................................................................................................................... 5
Torque specifications ......................................................................................................................................... 5
Special tools....................................................................................................................................................... 6
Drum removal .................................................................................................................................................... 9
Vibrator plate assembly ................................................................................................................................... 17
Removal of the right side of the drum .............................................................................................................. 19
Inspection and adjustment of vibration frequency............................................................................................ 24

SECTION 39 - FRAMES
Chapter 2 - Articulation
Description Page
Specifications..................................................................................................................................................... 1
Torque specifications ......................................................................................................................................... 1
Description ......................................................................................................................................................... 2
Special tools....................................................................................................................................................... 3
Disassembly....................................................................................................................................................... 5

SECTION 39 - FRAMES
Chapter 3 - Drum Segments and Scrapers
Description Page
Specifications..................................................................................................................................................... 1
Hardware torque ................................................................................................................................................ 1
Special tools....................................................................................................................................................... 1
Description ......................................................................................................................................................... 2
Segment installation........................................................................................................................................... 3

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 CONTENTS 5

SECTION 41 - STEERING
Chapter 1 - Control
Description Page
Specifications..................................................................................................................................................... 1
Special tools....................................................................................................................................................... 1
Description ......................................................................................................................................................... 2
Troubleshooting - Steering................................................................................................................................. 3
Disassembly and assembly of steering wheel ................................................................................................... 3

SECTION 41 - STEERING
Chapter 2 - Steering cylinders
Description Page
Specifications..................................................................................................................................................... 1
Special torques .................................................................................................................................................. 1
Special tools....................................................................................................................................................... 2
Removal of steering cylinders............................................................................................................................ 3
Replacing the seals............................................................................................................................................ 4

SECTION 41 - STEERING
Chapter 3 - Steering control valve
Description Page
Specifications..................................................................................................................................................... 1
Tightening torques ............................................................................................................................................. 1
Description ......................................................................................................................................................... 2
Special tools....................................................................................................................................................... 3
Disassembly....................................................................................................................................................... 4
Checking the steering elements......................................................................................................................... 7
Reassembly ....................................................................................................................................................... 7

SECTION 44 - WHEELS
Chapter 1 - Removal and installation
Description Page
Specification....................................................................................................................................................... 1
Torque specification........................................................................................................................................... 1
Special tool ........................................................................................................................................................ 1
Description ......................................................................................................................................................... 2
Disassembly of wheel ........................................................................................................................................ 3
Assembly ........................................................................................................................................................... 3

SECTION 50 - HEATER - AIR-CONDITIONING

Chapter 1 - Removal and installation
Description Page
Specifications..................................................................................................................................................... 1
Removal............................................................................................................................................................. 2
Air-conditioning system defects ......................................................................................................................... 4
Replacing (tightening) the belt ........................................................................................................................... 5
C7 - C9 - C11 - C15 604.13.235 - 09/2002
6 CONTENTS

SECTION 55 - ELECTRICAL CIRCUIT

Chapter 1 - Wiring diagram
Description Page
Electrical installation .......................................................................................................................................... 1
Functional description ........................................................................................................................................ 2
Electrical legend................................................................................................................................................. 4

SECTION 90 - PLATFORM, CAB

Chapter 1 - Operator’s compartment
Description Page
Torque specifications ......................................................................................................................................... 1
Operator’s compartment .................................................................................................................................... 2
Travel brake control adjustment......................................................................................................................... 8

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 00 - GENERAL INSTRUCTIONS - CHAPTER 1 1

SECTION 00 - MAINTENANCE

Chapter 1 - General Instructions

CONTENTS
Section 10000 Description Page
Introduction .................................................................................................... 1
Safety instructions ......................................................................................... 3
Environmental measures and health precautions ...................................... 6
Product identification .................................................................................... 8
Torque specifications ..................................................................................... 9

INTRODUCTION
This series of Vibratory Rollers is suitable for compac- The main purpose of this manual is to give the informa-
tion of all kinds of ground and for large and average- tion necessary for carrying out assembly and disas-
scale site pretaration in highway construction (construc- sembly of the machine as well as service repairs of
tion of highways, railways, airports), in hydro-engineer- main assemblies of the equipment. It contains technical
ing (construction of dams), in building construction and installation data, instructions on how to adjust the
(industrial areas, ports), and the like. machine and how to use special tools, fixtures and aids.
These machines are manufactured in compliance with The manufacturer continuously seeks to make product
the latest developments and standards, which ensure improvements on the basis of experience and latest
their safe function. developments in the field.
If the machine is used incorrectly, by untrained opera- For this reason, the manufacturer may make some
tors or for other purposes than those stipulated within, changes in drawings, descriptions and designs in this
there is a danger of an accident or damage to the manual.
equipment or injury to personnel.

C7 - C9 - C11 - C15 604.13.235 - 09/2002

2 SECTION 00 - GENERAL INSTRUCTIONS - CHAPTER 1

RIGHT, LEFT, FRONT AND REAR OF THE MACHINE

As used in this manual, the terms “right”, “left”, “front”
and “rear” indicate the sides of the machine as seen A
from the operator’s seat.
A. FRONT
B. REAR
C. RIGHT-HAND SIDE
D. LEFT-HAND SIDE

D C

B
CS00M511 1

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 00 - GENERAL INSTRUCTIONS - CHAPTER 1 3

SAFETY INSTRUCTIONS

GENERAL SAFETY INSTRUCTIONS 7. Attach a "Do not operate" warning note to the
The following safety instructions must be observed by steering wheel and leave it there for the duration of
ALL personnel repairing the machine. the service work.

1. Repairs may be carried out by skilled, trained and 8. Wash the equipment thoroughly. If you use steam,
experienced personnel only. do not expose electrical components and insula-
tion directly to the steam, otherwise cover them
2. When performing repairs, always use our service beforehand.
manual. Special instructions for the assembly work
are given in individual chapters of this manual. 9. Keep all parts absolutely clean when dismantling,
mounting, and servicing each assembly. Protect
3. Before putting the machine into operation familiar- removed parts from getting soiled.
ize yourselves with the machine controls as
explained in the “Operator’s Manual” and make 10. Clean the surface of dismantled parts and do the
sure that you are completely familiar with the necessary to ensure adequately dust-free working
machine. conditions and a suitable storage area.

4. Do not use the machine if you do not fully under- 11. Be careful when handling cleaning agents. Do not
stand all controls and until this know how the use fuel or other easy inflammable materials for
machine works. cleaning.

5. Familiarize yourself with the area where you will 12. Dry the cleaned parts and immediately cover with
work. anti-corrosive protective oil, never install corroded
parts.
6. Do not carry out any redesign work or modifica-
tions on the machine because you could compro- 13. Tools, hoists, safety equipment on chains, and
mise the safety of the equipment. other additional items must be serviceable and in
good condition.
7. Original parts and accessories have been
designed especially for this machine. 14. Use hoists and fasteners (ropes, chains) that have
sufficient lifting capacity and are in good condition.
8. Installation and use of spare parts not supplied by
the manufacturer of the machine or not authorized 15. Make sure that there is enough fresh air supply
by them can have negative effects on operational when starting up the equipment in an enclosed
characteristics and safe operation of the machine. area.

REPAIRING AND INSPECTING THE MACHINE

1. Wear working clothes and boots.
2. Use gloves when handling oils, fuel or coolant.
3. Protect your eyes with a full face shield when han-
dling the battery.
4. Place the equipment on a flat and firm surface
before starting repair. Secure the machine to pre-
vent spontaneous movement.
5. Secure the frame of the machine and the drum to
prevent rotation using a locking pin and a draw bar.
6. Before starting work remove the starter switch key,
disconnect the batteries and let hot parts cool
down.

C7 - C9 - C11 - C15 604.13.235 - 09/2002

4 SECTION 00 - GENERAL INSTRUCTIONS - CHAPTER 1

16. Before operating the equipment make sure there is 10. Fill new components with hydraulic oil before
nobody on the machine or close by. Starting up of installation.
the machine must always be announced with an
11. Rinse the hydraulic circuit after replacing a hydrau-
audible alarm, also after any pause in operation
lic component; clean the hydraulic reservoir as
before the equipment is restarted. Those present
well.
on the machine and dangerously close by must
leave the machine after the alarm has been 12. Replace the oil filter cartridge.
sounded.
13. Fill the hydraulic circuit with clean oil of the recom-
17. Do not adjust moving equipment. mended viscosity, but only when the engine has
been stopped.
18. When working (adjusting) on a running engine,
avoid touching hot and rotating parts. During work 14. Wipe off excess oil.
on a running engine, another person must be
15. Check connections for tightness and any oil leaks,
present that can easily access the emergency
before applying pressure to the system.
switch and must be in contact at all times with the
person performing the adjustment, to be able to 16. Do not adjust safety valves.
switch off the engine immediately when necessary.
17. After all work has been finished, recheck all con-
19. Use only approved makes of motor, gear and nections and replace all safety items.
hydraulic oil and coolant.
18. After finishing the work put all protective devices
back in place.
WORKING ON HYDRAULIC CIRCUITS
1. Make sure that no hydraulic circuit is under pres- 19. After putting the machine into operation.
sure before opening it. Hydraulic oil leaks under • Check the level in the hydraulic reservoir.
pressure may penetrate your skin and cause seri-
ous injury. • Check the output pressure of hydraulic pumps if
they have been replaced as well as safety valve
2. Mark all parts, hoses and pipes before removing pressure. Carry out the measurements at a tem-
them. perature of 40°C.
3. Do not operate hydraulic pumps and hydraulic
motors without oil. WORKING ON THE FUEL SYSTEM
Mixtures of gasoline and diesel (winter fuel) are as
4. There is danger of being scalded when handling
inflammable as gasoline.
hot oil.
1. Do not refuel in closed areas.
5. Do not warm oil to temperatures above 160°C
(320°F), oil or its fumes may ignite. 2. Wipe off excess fuel.
6. For cleaning and wiping hydraulic parts use lint 3. Do not smoke when working on the fuel system
free material. and do not use open frames. There is a danger
of fire.
7. When reassembling parts use hydraulic oil, not
grease, as a lubricant.
8. Clean screws and bolts carefully before installa-
tion, wash hoses and pipes and blow through them
using compressed air.
9. Always use new seals and packing in sealing
areas during re-installation.

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 00 - GENERAL INSTRUCTIONS - CHAPTER 1 5

WORKING ON ELECTRICAL WIRING 15. Never add sulfuric acid (H2SO4).

1. Disconnect the battery when carrying out any 16. Do not overturn the batteries because electrolyte
repairs on the charging circuit to avoid accidental could run out of the air vents in the battery.
short-circuits.
17. If acid (electrolyte) is spilled, rinse the area with
2. When dismantling, first disconnect the cable from water and neutralize it with lime.
the negative pole (-), then the cable from the posi-
tive one (+). 18. When the batteries are being charged, hydrogen is
released and, mixed with air, makes an explosive,
3. Do not disconnect batteries when the engine is easily combustible mixture. Do not use open
running. flames and do not smoke.
4. Connect the “minus” pole of the battery to the
chassis and the “plus” pole to terminal “B+” from WELDING ON THE MACHINE
the alternator. Opposite connection will cause the Before starting arc welding, disconnect all parts with
whole semi-conductor device to be destroyed. semi-conductors from electrical wiring, i.e.:
5. When starting with an auxiliary external supply, do • engine alternator,
not disconnect the supply before is the battery the
• hourmeter,
machine is charging. Make sure of the starting volt-
age of the auxiliary external supply, (for 24 V). • control unit under the instrument panel,
6. Do not put the alternator into no-load operation, i.e. • ground both the supply and the machine that is
with the wire disconnected from the “+” terminal being repaired,
and connected to the “D+” terminal.
• protect the supply point against moisture,
7. Do not check the presence of voltage in the wire by
• place the ground terminal close to the welded
sparking it on the chassis of the equipment.
joint,
8. Do not do anything that produces sparks.
• when parts are welded or when the machine is
9. When handling batteries, use protective rubber in the suspended position, insulate the point of
gloves and full face protection. current transfer to avoid current entering the
hoist, or use a non-conducting rope.
10. Protect your skin and clothes from stains caused
by electrolyte or lead particles.
SEALS
11. If electrolyte gets into your eyes, rinse them with 1. Always use new seals.
running water for 15 minutes. Then see a doctor as
soon as possible. 2. You can obtain seals kits in spare part form.
12. When electrolyte stains your skin or clothes, take HARDWARE TORQUE
off your clothes, wash the stained area with soapy
water or with a solution of baking soda and water 1. Use a torque wrench to obtain correct hardware
and see a doctor. torque.

13. In the event of accidentally swallowing electrolyte, 2. Fastening screw and nut are tightened according
drink as much milk or water as possible or a solu- to the table.
tion of milk of magnesia and immediately see a 3. Screw grades are shown normally on the screw
doctor. head.
14. Never pour distilled water into the cells unless the 4. Hardware torque is given in the tables.
operation of the machine or charging outside the
machine follows. In this case, the battery would 5. Threaded connections for hydraulics are tightened
discharge rapidly. as specified in the tables.
6. The given hardware torque specifications are valid
for dry screw threads.
7. Use new self-locking nuts only.

C7 - C9 - C11 - C15 604.13.235 - 09/2002

6 SECTION 00 - GENERAL INSTRUCTIONS - CHAPTER 1

ENVIRONMENTAL MEASURES AND HEALTH PRECAUTIONS

When repairing the machine, observe the general prin- 4. Oil products, coolants, batteries, and paint includ-
ciples of health protection and environment protection, ing organic thinners as well as cleaners and pre-
along with all laws, regulations, and guidelines related servatives should be always stored in their original
to these problems, as applicable to the territory where packaging and properly labeled. Do not store such
the machine is used. products in unlabeled bottles and other containers
because there is a danger of confusion. Confusion
HYGIENE with food or drinks is especially dangerous.
1. Oil products, coolants, battery acids, and paints 5. If your skin or eyes are accidentally splashed or
including thinners can be harmful to your health fumes inhaled, apply first aid immediately. In case
and they can cause serious injury. of accidental consumption of such products see
2. It is necessary to always observe safety and health your doctor immediately.
instructions enclosed with products and use per-
sonal protective aids when handling them. ECOLOGICAL PRECAUTIONS
1. Contents of machine systems and some parts of
3. Personnel in contact with these products during
the machine, when no longer in use, represent
servicing must observe the general principles relat-
great risks to the environment.
ing to conservation and keep in mind safety and
health guidelines as given by manufacturers of 2. The following products especially belong to this
such products, especially the following: category:
• protect the eyes and skin when working with • both organic and synthetic lubricating materials,
batteries, oils and fuel,
• protect the skin when handling oil products, • coolants,
paint, and coolants,
• battery acids and batteries themselves,
• workers should wash their hands properly after
• cleaning agents and preservatives,
finishing their work and apply proper healing
hand lotions, • all removed filters and filter elements,
• when working with the cooling system it is nec- • all used and discarded hydraulic and fuel hoses,
essary to observe the instructions in the manu- rubber - metals and the other elements exposed
als supplied with the machine. to the above products.
3. The above parts and materials must be handled,
after they had been discarded, in accordance with
prevailing national/regional regulations on environ-
mental protection and in conformance with direc-
tives relating to health conservation.
4. When hydraulic liquids, fuel, cooling systems and
their components are being removed it is neces-
sary to prevent spillage on the ground by using
retaining vessels and by plugging all openings.
5. In the event of leakage, the contaminated area-
must be immediately dried with sawdust, or similar
absorbing material.
6. Contaminated dirt must be removed to prevent fur-
ther contamination. The soil and absorbing mate-
rial must be disposed of safely.

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 00 - GENERAL INSTRUCTIONS - CHAPTER 1 7

FIRE PRECAUTIONS
1. From a fire risk point of view, the flammable liquids
used are divided into the following risk classes
II. Risk class
- oil
IV. Risk class
- mineral oils
- lubricants
- anti-freeze
2. The place where oil is being changed must not be
situated in an area where there is danger of explo-
sions or fire.
3. Notices showing that smoking and open flames are
not allowed must be installed there.
4. The receptacles used to catch drained flammable
liquids must be of adequate capacity.
5. Portable fire extinguishers must be available.
6. Oil and oil products should be handled in special
containers, e.g.: metal barrels, drums or cans.
7. Liquid containers must be properly shut and sealed
when stored.
8. The containers should have an air vent. They
should be always be stored with the air vent up and
there must be measures taken to prevent leakage.
9. The containers must be labeled with indelible
inscriptions showing their contents and flammabil-
ity class.

C7 - C9 - C11 - C15 604.13.235 - 09/2002

8 SECTION 00 - GENERAL INSTRUCTIONS - CHAPTER 1

PRODUCT IDENTIFICATION
Serial and type numbers are important for machine
identification and/or in case of warranty claims. A name
plate with basic machine data is attached to the left side
of the frame below the cab.

CS01A520B 2
A plate with the serial number of the Cummins engine is
attached to the fuel injection pump drive housing.
Serial numbers and data relating to major components
may be found on the components concerned.

CD00M009 3

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 00 - GENERAL INSTRUCTIONS - CHAPTER 1 9

TORQUE SPECIFICATIONS

FASTENING HARDWARE
Inspection and re-tightening Screws with metric threads
1. Regularly check that hardware is not loose. Torque
2. Use torque limiting wrenches to tighten screws and
Screw For screws For screws For screws
nuts.
size 5.8 (5 S) 8.8 (8 G) 10.9 (10 K)
Nm Nm Nm
M4 2 3 4
M5 4 6 8
M6 7 10 14
M8 16 22.5 32.5
M10 31.5 44 62
M12 53 75 105
M14 79 118 165
M16 113 165 226
M18 172 245 343
M20 226 314 441
M22 284 392 559
M24 392 549 755
NOTE: Lock nuts may be used a maximum of three
times when approved.

C7 - C9 - C11 - C15 604.13.235 - 09/2002

10 SECTION 00 - GENERAL INSTRUCTIONS - CHAPTER 1

SCREW TYPE HOSE CONNECTIONS

Screw type connections with “O” Rings

Nm
Wrench size Thread Hose Nominal Min Max
14 M12x1.5 6 20 15 25
17 M14x1.5 8 38 30 45
8
19 M16x1.5 45 38 52
10
10
22 M18x1.5 51 43 58
12
24 M20x1.5 12 58 50 65
14
27 M22x1.5 74 60 88
15
30 M24x1.5 16 74 60 88
32 M26x1.5 18 105 85 128
20
36 M30x2 135 115 155
22
41 25
36x2 166 140 192
46 28
50 M42x2 30 240 210 270
M45x2 35 290 255 325
50 38
M52x2 330 280 380
42

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 00 - GENERAL INSTRUCTIONS - CHAPTER 1 11

PLUGS AND NECKS

Table of tightening torques for necks and plugs with tight-
ening edge, or with flat packing:

Ø Ø Ø
CS01C502 4 CS01C503 5
Neck torque Plugs torque
Ø Nm Ø Nm
G 1/8“ 25 G 1/8“ 15
G 1/4“ 40 G 1/4“ 33
G 3/8“ 95 G 3/8“ 70
G 1/2“ 130 G 1/2“ 90
G 3/4“ 250 G 3/4“ 150
G 1“ 400 G 1“ 220
G 11/4“ 600 G 11/4“ 600
G 11/2“ 800 G 11/2“ 800
M 10x1 25 M 10x1 13
M 12x1.5 30 M 12x1.5 30
M 14x1.5 50 M 14x1.5 40
M 16x1.5 60 M 16x1.5 60
M 18x1.5 60 M 18x1.5 70
M 20x1.5 140 M 20x1.5 90
M 22x1.5 140 M 22x1.5 100
M 26x1.5 220 M 26x1.5 120
M 27x1.5 250 M 27x1.5 150
M 33x1.5 400 M 33x1.5 250
M 42x1.5 600 M 42x1.5 400
M 48x1.5 800 M 48x1.5 500

C7 - C9 - C11 - C15 604.13.235 - 09/2002

12 SECTION 00 - GENERAL INSTRUCTIONS - CHAPTER 1

NOTES

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 00 - SPECIFICATIONS - CHAPTER 2 1

SECTION 00 - MAINTENANCE

Chapter 2 - General Specifications

CONTENTS
Section 10000 Description Page
Description of the machine ........................................................................... 1
Fluids and lubricants ..................................................................................... 2
Specifications ................................................................................................. 5
Overall machine dimensions ...................................................................... 10

DESCRIPTION OF THE MACHINE

This vibratory roller is a self-propelled compaction Towing unit
machine consisting of two articulated sections, i.e: the
This consists of a welded frame with the articulation
drum and the towing unit.
support and hydraulic travel motors in front and the fuel
Drum unit tank, batteries and tool box at the rear. The hydraulic
reservoir, operator’s compartment and ROPS frame
This consists of the frame in which the drum with the
and cab are mounted on top.
travel drive and vibration drive is placed. Two levels of
amplitude, which can be selected together with the cor- The static linear load and dynamic parameters for this
responding frequency, make it possible to compact machine place it in the heavy vibratory roller category.
materials with different characteristics. Two scrapers
placed on the front side of the beam and on the rear
side on the cross member of the drum frame are pro-
vided for removing any soil adhering to the drum.
Articulation
Connects both units of the roller and enables independ-
ent horizontal and vertical movement of both sections.

C7 - C9 - C11 - C15 604.13.235 - 09/2002

2 SECTION 00 - SPECIFICATIONS - CHAPTER 2

ATTACHMENTS The ROPS protection frame

Tamping segments This protects the driver in case of the machine overturn-
These segments make it possible to convert a smooth ing. Data concerning the frame is to be found on the
drum for tamping compaction duties. plate.

Dozer blade ASC lock

This attachment is useful for spreading bulk soil and for This makes it possible to negotiate rough terrain
leveling the area being compacted. The arms of the (grades) with better traction and helps when loading on
blade are articulated and fixed to the frame of the drum. a trailer or trying to free the machine in mud, etc.
The blade is lifted and lowered using two bracket-
mounted linear hydraulic cylinders on the right and left
side drum frame members.

FLUIDS AND LUBRICANTS

Lubricants must have the correct properties for each
application.

! WARNING !
The conditions of use for individual fluids and lubri-
cants must be respected.

ENGINE OIL
IMPORTANT: Use high quality oil and follow the oil
changing intervals so as to ensure maximum engine
life.
Categories of oil to be used: API CE - CCMC D5
NOTE: In certain countries, if CE grade oils are not to
be found, it is possible to use CC/CD grade oils, but in
this case the oil must be changed more frequently.
The type of oil to use depends on ambient temperature:
- SAE 15W40: All seasons
- SAE 10W30: Winter
- SAE 5W30: Arctic
The following table gives the temperature ranges for dif-
ferent oils, depending on their viscosity.
NOTE: Do not put any Performance Additive or other
additive in the sump. Oil change intervals shown in this
manual are based on tests carried out on lubricants.
CS00N532 1

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 00 - SPECIFICATIONS - CHAPTER 2 3

HYDRAULIC FLUID ANTI-FREEZE/ANTI-CORROSION

Use high quality hydraulic fluid which is suitable for use Use anti-freeze in all seasons to protect the cooling sys-
at high pressures. tem from corrosion and freezing.
The type of fluid use depends on ambient temperature: For areas where ambient temperature is over -36°C,
VG68: 0°C to +40°C use a blend of 50% ethylene-glycol based anti-freeze.
HV100: high temperatures
For areas where the temperature is below -36°C, it is
HV46: temperatures below -8°C
advisable to use a blend of 40% water and 60% anti-
HV32: temperatures below -13°C
freeze.
PLANETARY OIL
Use extreme pressure type oil, of the Molydisulfide.
GREASE
Use extreme pressure grease of the NLGI grade 2 cat-
egory.
FUEL
Use fuel which is to ASTM (American Society for Test-
ing and Materials) D975 standard.
Use grade No. 2 fuel. The use of other types of fuel can
result in a loss of power and may cause high fuel con-
sumption.
When the temperature is very cold, the use of a mixture
of No. 1 and No. 2 fuel is permitted. See your fuel ven-
dor for winter fuel requirements in your area.
If the temperature falls below the fuel cloud point (point
at which wax begins to form) the wax crystals will cause
power loss or will prevent the engine from starting.
IMPORTANT: In cold weather, fill the fuel tank at the
end of the day’s work, in order to prevent the formation
of condensation.
Long storage can lead to the accumulation of impurities
and condensation in the fuel. Engine trouble can often
be traced to the presence of water in the fuel.
The storage tank must be placed outside and the tem-
perature of the fuel should be kept as low as possible.
Drain off water and impurities regularly.

C7 - C9 - C11 - C15 604.13.235 - 09/2002

4 SECTION 00 - SPECIFICATIONS - CHAPTER 2

FLUID AND LUBRICANT CAPACITIES AND SPECIFICATIONS

Components Fluids and lubricants C7 - C9 C11 - C15

SAE 15W40 - API CE/SGE, ACEA E1-E2,
Engine 11.2 litres 16.3 litres
CCMC D2-D3 - 10W30 - 5W30 oil
Hydraulic system HV VG 68 73 litres 90 litres
Planetary API GL5 - SAE 80W90 oil 2.5 litres 4.2 litres
Axle API GL5 - SAE 80W90 oil 2 x 2.5 litres 2 x 2.8 litres
Fuel system Grade N°2 fuel 275 litres 410 litres
Machine articulation Molydisulfide as needed as needed
Cooling system Coolant - Water - Anti-freeze 19 litres 25 litres
Drum vibration SAE 15W40 - 10W30 - 5W30 oil 6.7 litres 8 litres
Batteries Distilled water as needed as needed
Windshield washers Water - Anti-freeze 2.75 litres 2.75 litres
Unslaked calcium chlorides + calcium hydroxide
Cooling system of the drum - -
+ water

ENVIRONMENT
Before carrying out any maintenance operation on this
machine and before disposing of used fluids or lubri-
cants, always think of the environment. Never throw oil
or fluid on the ground and never place it in leaking
receptacles.
Contact your local ecological recycling center or your
Dealer to obtain information on the correct method of
disposing of these materials.

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 00 - SPECIFICATIONS - CHAPTER 2 5

SPECIFICATIONS

ENGINE

C7 C9 C11 C15
Make Cummins
Type B3.9-C100 B5.9-C148
Number of cylinders 4 6
Power rating 75 kW (100 HP) 110 kW (148 HP)
Standard ISO 3046/1 (DIN 6271)
Rated speed 2200 rpm 2200 rpm

STEERING

C7 C9 C11 C15
Oscillator angle ± 12° ± 10°
Steering angle - ± 36°
Turning radius:
Inner (edge) 3090 mM 3050 mm
Outer (contour) (without dozer blade) - 5370 mm 5395 mm
Outer (contour) (with dozer blade) - 5738 mm 5738 mm

CAPACITIES

C7 C9 C11 C15
Fuel tank 275 litres 410 litres
Engine oil 11.2 litres 16.3 litres
Cooling system 19 litres 25 litres
Hydraulic system 73 litres 90 litres
Drum gearbox 2.5 litres 4.2 litres
Vibrating drum 6.7 litres 8 litres
Wheel gears 2 x 2.5 litres 2 x 2.8 litres
Cooling system of the drum - -

C7 - C9 - C11 - C15 604.13.235 - 09/2002

6 SECTION 00 - SPECIFICATIONS - CHAPTER 2

ELECTRICAL SYSTEM

C7 C9 C11 C15
Voltage 24 volts
Batteries 2 x 61 Ah 2 x 100 Ah

WHEELS

C7 C9 C11 C15
Size of tires 14.9 x 24" 23.1 x 26"
Tread (with smooth drum) DIAMOND 8 PR UK5 10 PR
(with tamping drum) - TR1 10 PR
Average ground contact pressure 304 kPa
Tire inflation 150 kPa (21.7 PSI) 160 kPa (23.2 PSI)

TRAVEL

C7 C9 C11 C15
Drive axles 2
Number of travel speeds 4
1st speed range
Position of the shifter for working speed
0 - 2.5 km/h
1st position of the pre-selector
2nd position of the pre-selector 0 - 3.5 km/h
3rd position of the pre-selector 0 - 4.7 km/h 0 - 5.3 km/h 0 - 4.5 km/h

2nd speed range

Position of the shifter for transport speed (hare) 0 - 11 km/h 0 - 10.6 km/h 0 - 10 km/h
Pre-selective gear control disengaged (0 - 6.83 mph) (0 - 6.58 mph) (0 - 6.2 mph)

Transversal stability - straight 50° 46° 36° 37°

Brakes
Hydrostatic
Services
Parking and emergency Multi-disc
Pratical gradeability
45%
Without vibration
With vibration 45% 45%
Vibration
30/40 Hz 32/35 Hz 29/35 Hz
Frequency
Amplitude 1.7/0.86 mm 1.85/0.96 mm 1.85/1.15 mm 2/1 mm

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 00 - SPECIFICATIONS - CHAPTER 2 7

WEIGHTS

C7 C9 C11 C15
Operating weight (CECE) * with cab and ROPS frame 7255 kg 8935 kg 11 665 kg 14 550 kg

Operating weight (CECE) - maximum 7675 kg 9355 kg 12 865 kg 15 750 kg

Drum load weight 4020 kg 5315 kg 7020 kg 10 160 kg
Ballast 420 kg 1200 kg 1200 kg
Cab 220 kg
ROPS frame 230 kg
Three tamping compaction segments 1090 kg 1680 kg

Tires with liquid ballast 2 x 210 kg 2 x 600 kg

* When using tamping compaction segments or liquid tire ballast, the basic machine weight figures shown must be
increased accordingly.

EQUIPMENT
C7 - C9
Standard Options
Tamping foot kit (if not fitted)
Lockable vandal guard
Air-conditioning
Both drum and wheels are hydrostatically driven
(Smooth drum) Tires 14.9-24 TT tread R1 (TD02)
Double mode vibration (C9)
(8 PR) instead of standard ones
Interwheel differential lock
(Tamping drum) Tires 14.9-24 tread R3 (T329
Articulated chassis
DIAMOND) (8 PR) instead of standard ones
Halogen working lamps
Tire ballast liquid filling to 0°C (C7)
(Smooth drum) Tires 14.9-24 tread R3 (T329
Tire ballast liquid filling to -25°C (C7)
DIAMOND) (8 PR)
Compaction indicator
(Tamping drum) Tires 14.9-24 TT tread R1 (TD02)
Turn indicators
(8 PR)
Rotating beacon
Tire ballast liquid filling to -25°C (C9)
Electro-hydraulic cabin and hood tilting
Hand-pump hood and cabin tilting
Differential lock interaxle ASC
ROPS protection
Articulation joint lock oscillation
Engine speed indicator
Fan safety screen
Alternator safety screen
Back-up alarm

C7 - C9 - C11 - C15 604.13.235 - 09/2002

8 SECTION 00 - SPECIFICATIONS - CHAPTER 2

C11 - C15
Standard Options
Tamping foot kit (if not fitted)
Lockable vandal guard
Air-conditioning
Single lever control
Tires 23.1 x 26" TR1 (10 PR)
Both drum and wheels are hydrostatically driven
Tire ballast liquid filling to 0°C
Double mode vibration
Tire ballast liquid filling to -25°C
Interaxle differential lock
Compaction indicator
Articulated chassis
Turn indicators
Halogen working lamps
Rotating beacon
Tires 23.1 x 26" tread UK 5 (10 PR)
Dozer blade (if not fitted)
Tire ballast water filling device
ROPS protection
Engine air pre-cleaner
Fan safety screen
Alternator safety screen
Back-up alarm

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 00 - SPECIFICATIONS - CHAPTER 2 9

NOISE AND VIBRATION LEVELS

Internal noise
The acoustic pressure level affecting the driver during
travel (measured according to EN 11 202 on sand):

C7 - C9 C11 - C15
1) With door closed
Using vibration 81 dB 81 dB
Without vibration 77 dB 78 dB
2) With door open
Using vibration 84 dB 91 dB
Without vibration 81 dB 90 dB
External noise
Measured according ISO 6393 on concrete, machine stationary 104 dB 108 dB

Vibration
The mean effective value of vibration acceleration:

- Transferred to the hands (measured according to ISO 5349 on sand, using vibration): aw < 2.5 m/s2 (vectorial sum).

- Transferred to the body (measured according to EN 1032 on sand, using vibration): aw < 0.5 m/s2 (vectorial sum).

C7 - C9 - C11 - C15 604.13.235 - 09/2002

10 SECTION 00 - SPECIFICATIONS - CHAPTER 2

OVERALL MACHINE DIMENSIONS

E
F
M
C D
B L
A K H
G J

CS01C501 2

C7 C9 C11 C15
A 2.560 m 2.820 m
B 1.300 m 1.440 m

C 0.385 m 0.420 m
D 0.375 m 0.430 m
E 2.890 m 3.030 m

F 2.200 m 2.500 m
G 5.190 m 5.195 m 5.686 m
H 1.680 m 2.200 m

J 1.880 m 1.930 m 2.450 m 2.500 m

K 0.095 m 0.120 m 0.118 m 0.142 m
L 0.025 m 0.020 m 0.028 m

M 1.400 m 1.640 m

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 00 - MAINTENANCE - CHAPTER 3 1

SECTION 00 - MAINTENANCE

Chapter 3 - Troubleshooting
CONTENTS
Section 10000 Description Page
Troubleshooting - Engine .............................................................................. 2
Troubleshooting - Hydraulic system oil overheating - emulsifying .......... 3
Troubleshooting - Vibration .......................................................................... 3
Troubleshooting - Travel ............................................................................... 5
Troubleshooting - Brakes .............................................................................. 6
Troubleshooting - Steering ........................................................................... 6

C7 - C9 - C11 - C15 604.13.235 - 09/2002

2 SECTION 00 - MAINTENANCE - CHAPTER 3

NOTE: Items between brackets ( ) refer to the Wiring Diagram, Section 55, Chapter 1.

TROUBLESHOOTING - ENGINE

Problem Possible cause Remedy

Fuel tank empty Fill the fuel tank
Fuel filter restriction Change the filter
Contaminants or water in fuel circuit Empty the tank and decontaminate the circuit
Check the fuel lines and connections (leaks).
Air in fuel circuit
Bleed the circuit. See Operator’s manual.
Engine stops suddenly Hydraulic oil gauge defective Replace gauge (S14)
while traveling
Look for signs of leakage from the hydraulic
Hydraulic oil reservoir level too low
circuit. Repair if necessary and fill the reservoir
Emergency shutdown button pressed
Release the emergency stop button
down
Lower the safety arm and check the contactor
RH safety arm contactor position
position
Fuel tank empty Fill the tank
Fuel filter restriction Replace the filter
Defective charge pump Check the pump and replace it if necessary
Empty the fuel tank and decontaminate the
Contaminants or water in fuel circuit
system
Check the fuel liner and connections (leaks).
Starter motor runs but Air in fuel circuit
Bleed the circuit
engine does not start
Incorrect injection pump timing Check the injection pump timing
Look for signs of leakage from the hydraulic
Hydraulic oil reservoir level too low or
circuit. Repair if necessary and fill the reservoir.
hydraulic oil gauge defective
Replace the gauge if necessary
Check the electrical circuit between fuse (F3),
Engine shutdown electro-valve
relay (K3) and engine shutdown electro-valve
activated
(Y5)
Make sure that:
- The battery master switch is on and the travel
Starting up procedure not being control is in neutral
followed - The emergency cut-out button is not pressed
down
- The (S10) safety arm is lowered
Check and charge the batteries. Replace them if
Starter motor does not run Batteries dead
necessary
and engine does not start
Clean, inspect and tighten the terminal nuts.
Corroded or loose battery terminals
Replace the terminals if necessary
Check continuity between switch (S3), fuse (F3),
switches (S10), (S11) and (S13), relay (K4) and
Electrical circuit defective
the starter motor. If continuity is good, check out
each component
Defective starter motor Repair or replace the starter motor

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 00 - MAINTENANCE - CHAPTER 3 3

TROUBLESHOOTING - HYDRAULIC SYSTEM OIL OVERHEATING - EMULSIFYING

Problem Possible cause Remedy

Clogged radiator fins Clean radiator fins
Check travel, vibration and steering circuit valve
Incorrect valve pressure setting
pressure settings. Adjust if necessary
Seized drum bearings (too much
Check drum bearings and replace if necessary
Hydraulic oil overheating pressure on vibrating circuit)
Steering articulation seized (too much Check steering articulation pin and bushings.
pressure on steering circuit) Repair if necessary
Hydraulic oil contaminated or of wrong
Drain the circuit and fill with the correct oil
viscosity
Check hoses and hose tightness on the suction
Air getting into steering pump suction
circuit. Tighten the clamps and replace the
circuit
Hydraulic oil aerating hoses and clamps if necessary
Hydraulic oil contaminated or of wrong
Drain the circuit and fill with the correct oil
viscosity

TROUBLESHOOTING - VIBRATION

Problem Possible cause Remedy

Breather loose or defective Tighten the breather or replace it if necessary
Cover 7 & 8 screws loose; see section Tighten screws to the correct torque; see
39 chapter 1 Section 39, chapter 1
O-rings 57 on covers defective; see Remove the covers and replace the seals; see
Oil leaking from roller section 39 chapter 1 Section 39, chapter 1
Vibration hydraulic motor shaft Remove the hydraulic motor shaft and replace
defective the seal
Plate/hub seal (22) defective; see Remove the plate and hub and replace the seal;
section 39 chapter 1 see Section 39, chapter 1
Travel control in wrong position Put the control in a suitable position
Adjust engine speed to over 2000 rpm see
Engine speed below 2000 rpm
section 39 chapter 1
Check the (S18), (S19) and (S20) switches, the
(Y9) and (Y10) electro-valves, the (K5) and (K7)
Electrical circuit defective
relays, plug the corresponding electrical
connections
Adjust the pilot pressure relief valve on the travel
Pilot pressure below 28 bar for C7, C9
pump, see section 35 chapter 3 and 4. Repair or
and C15; 42 bar for C11
replace if necessary, see section 29 chapter 1
Vibratory system not Steering pump defective, steering not
working Repair or replace the steering pump
working
Adjust the vibration circuit safety valves see
Vibration safety valves out of
section35 chapter 3 and 4. Repair or replace if
adjustment
necessary, see section 29 chapter 1
Internal leakage or worn vibration
pump. Seal off hydraulic motor supply If this pressure is not obtained, repair or replace
lines at the pump outlets and check the pump. If the pressure is obtained, check
maximum pressure (400 bar) (5801 vibration hydraulic motor leak off.
psi)
Vibration motor leakage exceeding 15l/
Repair or replace the vibration hydraulic motor
min

C7 - C9 - C11 - C15 604.13.235 - 09/2002

4 SECTION 00 - MAINTENANCE - CHAPTER 3

TROUBLESHOOTING - VIBRATION (continued)

(

Problem Possible cause Remedy

Check the (S18) switch, the (Y9) and (Y10)
Electrical circuit defective
electro-valves, repair or replace if necessary
Vibratory system only Adjust the vibration circuit safety valve section
One of the safety valves is out of
works in one selected 35 chapter 3 and 4. Repair or replace if
adjustment
position necessary, see section 29 chapter 1
Check the vibration motor relief valve and spool.
Return circuit pressure too high
Repair or replace if necessary see 35 chapter 2
Replace the bearings and check the vibration
Bearings (28) seized or damaged.
system operates freely; see Section 39, chapter
Vibratory system not Filings detected in drained drum oil
1
working (hydraulics OK)
Coupling between hydraulic motor and
Replace the coupling shaft and pinion
vibration system defective
Mechanical adjustment between Adjust to ensure contact at 2000 rpm section 39
Vibratory system works at throttle stop and S20 switch section 1
low engine speed
S20 switch defective Replace the switch
Adjust the mini or maxi frequency; see Section
Poor adjustment
39, chapter 1
Vibration safety valves out of Adjust the safety valves on the vibration circuit;
adjustment repair or replace if necessary
Vibratory system not
reaching frequency level Internal leakage or worn vibration
If this pressure can not be obtained, repair or
required pump. Seal off hydraulic motor supply
replace the pump. If the pressure is obtained,
lines at the pump outlets and check
check the vibration hydraulic motor leak off
maximum pressure 400 bar (5801 psi)
Vibration motor leakage exceeding 15l/
Repair or replace the vibration hydraulic motor
min (3.96 gal/mn)

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 00 - MAINTENANCE - CHAPTER 3 5

TROUBLESHOOTING - TRAVEL

Problem Possible cause Remedy

If the machine travels when the pressure switch
Brake pressure switch defective
is disconnected, replace the pressure switch
Check continuity between fuse (F3), relay (K6)
and controls (S16) and (S17), as well as
Electrical circuit defective between control box (A3) and electro-valve
(Y13). If there is continuity, check each
component
Set the travel circuit safety valve pressure to 350
Machine will not travel Travel safety valves out of adjustment bar for C7, C9 and 420 bar for C11. Repair or
replace if necessary see section 35 chapter 3
Internal leakage or worn travel pump. If this pressure can not be obtained, repair or
Seal off hydraulic motor supply lines at replace the pump. If the pressure is obtained,
the pump outlets and check maximum check the travel hydraulic motor leak off.
pressure 350 bar for C7, C9 and 420 Repair or replace if necessary see section 35
bar for C11. chapter 3
Travel hydraulic motor internal leakage Replace a hydraulic motor with leak off above
higher than 5 l/min 5 l/min
Set the travel circuit safety valves to 350 bar for
Travel safety valves out of adjustment C7, C9 and 420 bar for C11. Repair or replace if
necessary see section 35 chapter 3
Internal leakage or worn travel pump. If this pressure can not be obtained, repair or
Seal off hydraulic motor supply lines at replace the pump. If the pressure is obtained,
Travel lacks power
the pump outlets and check maximum check the travel hydraulic motor leak off.
pressure 350 bar for C7, C9 and 420 Repair or replace if necessary see section 35
bar for C11. chapter 3
Travel hydraulic motor internal leakage Replace a hydraulic motor with leak off above
higher than 5 l/min 5 l/min
Check continuity between relay (K6), control
High speed travel electric control
(S16) and electro-valves (Y7), (Y8) and (Y14). If
Machine only travels in high defective
there is continuity, check each component
speed
Travel motor cylinder displacement Check the cylinder displacement control pistons.
controls defective Repair or replace if necessary
Set the travel circuit safety valves to 350 bar for
Travel safety valves out of adjustment C7, C9 and 420 bar for C11. Repair or replace if
Machine will not travel in necessary see section 35 chapter 3
Forward or Reverse and
lacks power on one side Check the relief valve and control spool on the
Drum hydraulic motor return circuit
drum travel motor. Repair or replace if
pressure too high
necessary

C7 - C9 - C11 - C15 604.13.235 - 09/2002

6 SECTION 00 - MAINTENANCE - CHAPTER 3

TROUBLESHOOTING - BRAKES

Problem Possible cause Remedy

Brake application procedure not being Make sure travel control is in neutral and that the
followed correctly emergency brake is not on

Brakes do not apply Check continuity between fuse (F3), relay (K5),
diode (V1), the (A2) timer and electro-valve
Electrical circuit defective
(Y6). If there is continuity, check each
component
Steering pressure switch (S15)
Replace pressure switch (S15)
Brakes remain on when defective
steering wheel is turned Check continuity between fuse (F3), steering
Electrical circuit defective
pressure switch (S15) and the (A2) timer
Steering pressure switch (S15)
With the engine running, Replace pressure switch (S15)
defective
the brakes remain on (they
Check the (A2) timer voltage and replace it if
come off when the steering (A2) timer defective
necessary
wheel is turned
Brake electro-valve seized Repair or replace the electro-valve

TROUBLESHOOTING - STEERING

Problem Possible cause Remedy

Check pressure at M5, adjust the main relief
Main relief valve defective
valve and replace if necessary

Steering ineffective on Steering control valve defective Replace the control valve
rough ground Steering pump defective Repair or replace the pump
Leaking steering cylinder Repair or replace the cylinder
Steering column broken or damaged Repair or replace the steering column
Overset the main relief valve, check pressure at
Machine will only steer in
Secondary relief valve defective M5 and adjust the secondary relief valve or
one direction
replace it if necessary

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 00 - GENERAL INSTRUCTION - CHAPTER 4 1

SECTION 00 - GENERAL INSTRUCTION

Chapter 4 - Tooling
CONTENTS
Section 00000 Description Page
Tooling and equipment .................................................................................. 1

The following data is for general guidance. Where specific data or dimension are required and not quoted in this sec-
tion, refer to the section in the Repair Manual relating to the component under repair.
IMPORTANT: The following Tool listing is for all applications (unless otherwise stated).

TOOLING AND EQUIPMENT

C15
C11
C7
C9
Figures* Description Used Part No.

10-1-01 Hood support For holding hood in raised position ND080080 X X X X

10-1-02 Engine support For supporting engine ND080183 X X X X
10-1-03 Hook For lifting hood ND101778 X X X X
29-1-01 Cab support For holding cab in raised position ND080078 X X X X
29-1-02 Centering plate For centering coupling clutch ND080155 X X X X
Hydraulic cylinder For assembling piston in hydraulic
35-1-01 ND101783 X X X X
piston installer cylinder
35-1-02 Spanner For gland disassembly ND101784 X X X X
35-1-03 Spanner For gland disassembly ND101785 X X X X
35-1-04 Gland wrench For gland disassembly ND107335 X X X X
35-1-05 Gland wrench For gland disassembly ND107337 X X
35-1-06 Gland wrench For gland disassembly ND101328
For clamping drum rubberized metal
39-1-01 Bolts ND080073 X X X X
pieces
39-1-02 Driver For installing bushing in cam ND080145 X X X X
39-1-02 Driver For installing bushing in cam ND080202
39-1-03 Sleeve For setting up positioning pin ND080146 X X
Axial play feeler
39-1-04 For checking bearing end play ND080147 X X X X
gauge
39-1-05 Handling shaft For plates and vibrator ND080148 X X
39-1-05 Handling shaft For plates and vibrator ND080203
39-1-06 Handling jig For removing consoles from drum ND080149 X X
39-1-06 Handling jig For removing consoles from drum ND107327 X X
39-1-07 Cam installer For positioning cam ND080213 X X
39-1-07 Cam installer For positioning cam ND080297 X X
For establishing tapened bearing
39-1-08 Special wrench ND080219
pre-load in hub
For establishing tapened bearing
39-1-08 Special wrench ND101777 X X X X
pre-load in hub
39-1-09 Special wrench For removing mounting nut ND080229 X X X X

C7 - C9 - C11 - C15 604.13.235 - 09/2002

2 SECTION 00 - GENERAL INSTRUCTION - CHAPTER 4

C15
C11
C7
C9
Figures* Description Used Part No.

39-1-10 Cam installer For cam installation ND081205

39-1-11 Handling ring For right and left shaft ND081213
39-1-12 Extractor For removing vibrator shaft ND081983 X X
39-1-13 Clamp For vertical installation of the drum ND090512 X X
39-1-14 Clamp For securing drums ND090535 X X X X
39-1-15 Wrench For vibration hydro-motor assembly ND090605 X X X X
39-1-16 Ring installer For oil ring installation ND101776 X X X X
39-1-16 Ring installer For oil ring installation ND107119
Disassembly of hub, vibrator plate
39-1-17 Remover ND101781 X X X X
and bearing
39-1-18 Frequency tester For vibration frequency check ND103942 X X X X
39-1-19 Handling link For removing consoles from drum ND107322
39-1-20 Handling link For removing consoles from drum ND107323
5.6 t double-hook
39-2-01 For removing drum ND090530 X X
chain
14 t double-hook
39-2-01 For removing drum ND090586 X X
chain
Handling chain four
39-2-02 For removing drum ND090588
four hook
39-2-03 Wrench For removing nut ND090610 X X X X
39-2-03 Wrench For removing nut ND107334
39-2-04 Suspension hook For handling bearing ND103875 X X X X
39-2-05 Bearing removal tool For removing bearing ND101782 X X X X
For assembly/disassembly of
41-1-01 Special washer ND080755 X X X X
steering wheel
For removing pressure relief valve
41-3-01 Separator 8440798201 X X
on steering control valve
Mandrel with aligning For seal ring flange on steering
41-3-02 8470798001 X X
bush control valve
For measuring the valve piston and
41-3-03 Gauge holder 8470798101 X X
drive shaft on steering control valve
For measuring the valve piston and
41-3-04 Gauge insert 13 mm 8470798552 X X
drive shaft on steering control valve
44-1-01 Handling jig For wheel removal ND080533 X X
44-1-01 Handling jig For wheel removal ND107324
44-1-01 Handling jig For wheel removal ND107325 X X

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 00 - GENERAL INSTRUCTION - CHAPTER 4 3

35-1-01
ND101783 - Hydraulic cylinder piston installer 6

10-1-01
ND080080 - Hood support 1

10-1-02
ND080183 - Engine support 2

35-1-02
ND101784 - Spanner 7

35-1-03
ND101785 - Spanner 8

35-1-04
10-1-03 ND107335 - Gland wrench 9
ND101778 - Hook 3

35-1-05
29-1-01 ND107337; ND101328 - Gland wrench 10
ND080078 - Cab support 4

39-1-01
29-1-02 ND080073 - Bolts 11
ND080155 - Centering plate 5

C7 - C9 - C11 - C15 604.13.235 - 09/2002

4 SECTION 00 - GENERAL INSTRUCTION - CHAPTER 4

39-1-02 39-1-06
ND080145; ND080202 - Driver 12 ND080149; ND107327 - Handling jig 16

39-1-03
ND080146 - Sleeve 13

39-1-07
ND080213; ND080297 - Cam installer 17

39-1-04
ND080147 - Axial play feeler gauge 14

39-1-08
ND080219; ND101777 - Special wrench 18

35-1-05
ND080148; ND080203 - Handling shaft 15

39-1-09
ND080229 - Special wrench 19

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 00 - GENERAL INSTRUCTION - CHAPTER 4 5

39-1-10
ND081205 - Cam installer 20

39-1-12
ND081983 - Extractor 22

39-1-13
39-1-11 ND090512 - Clamp 23
ND081213 - Handling ring 21

39-1-14
ND090535 - Clamp 24

C7 - C9 - C11 - C15 604.13.235 - 09/2002

6 SECTION 00 - GENERAL INSTRUCTION - CHAPTER 4

39-1-15
ND090605 - Wrench 25

39-1-16
ND101776; ND107119 - Ring installer 26
39-1-19
ND107322 - Handling link 29

39-1-17
ND101781 - Remover 27

39-1-20
ND107323 - Handling link 30

39-1-18
ND103942 - Frequency tester 28

39-2-01
ND090530; ND090586 - Double-hook chain 31

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 00 - GENERAL INSTRUCTION - CHAPTER 4 7

41-1-01
ND080755 - Special washer 36

41-3-01
39-2-02 8440798201 - Tool 37
ND090588 - Handling chain four hooks 32

39-2-03
41-3-02
ND090610; ND107334 - Wrench 33
8470798001 - Mandrel with aligning bush 38

41-3-03
39-2-04 8470798101 - Gauge holder 39
ND103875 - Suspension hook 34

39-2-05 41-3-04
8470798552 - Gauge insert 13 mm 40
ND101782 - Bearing removal tool 35

C7 - C9 - C11 - C15 604.13.235 - 09/2002

8 SECTION 00 - GENERAL INSTRUCTION - CHAPTER 4

44-1-01
ND080533; ND107324; ND107325 - Handling
jig 41

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 10 - ENGINE - CHAPTER 1 1

SECTION 10 - ENGINE

Chapter 1 - Removal and installation

CONTENTS
Section 21603 Description Page
Specifications ................................................................................................. 1
Description ..................................................................................................... 2
Torque specifications .................................................................................... 4
Special tools ................................................................................................... 4
Removal .......................................................................................................... 6
Installation .................................................................................................... 13
Accelerator cable assembly removal and installation .............................. 13

IMPORTANT: All repair work done to the engine during the warranty period must be done by a Cummins service
center.

SPECIFICATIONS

C7 C9 C11 15
Manufacturer Cummins

Type of the engine B3.9-C100 B5.9-C148

Number of cylinders 4 6

Cylinder bore 102 mm 102 mm

Stroke 120 mm 120 mm

Total displacement 3900 cm3 (3.9 l) 5880 cm3 (5.9 l)

Power rating ISO 3046/1 (DIN 6271) 75 kW (100 HP) 110 kW (148 HP)
Rated speed 2200 rpm 2200 rpm
Maximum torque 404 Nm 597 Nm
Fuel consumption during normal operation 9 l/h - 11.8 l/h 12.5 l/h
Fuel filters Fleetguard Fleetguard
Oil filter Fleetguard Fleetguard
Air filter Donaldson Donaldson
Air filter element Donaldson Donaldson
Safety air filter element Donaldson Donaldson
Cooling system Water cooled engine with radiator
CENTA CENTA
Drive coupling
CF-H-030-1 Sa 02 CF-H-030-1 Sa 03

C7 - C9 - C11 - C15 604.13.235 - 09/2002

2 SECTION 10 - ENGINE - CHAPTER 1

DESCRIPTION

28 3
23
23 31
48

29
64
51

86
56 64

5
2 6

47
12 1 64

51
64

CS01D543 1
1. Bracket
2. Bracket
3. Clamp
5. Support
6. Support
12. Flange
23. Clamp
28. Screw
29. Throttle lever
31. Pipe holder
47. Screw M10 x 35
48. Screw M10 x 80
51. Screw M12 x 35
56. Screw M16 x 20
64. Nut M12
86. Coupling

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 10 - ENGINE - CHAPTER 1 3

27
8

35

53

30
8

35
CS01D544 2
8. Bracket
27. Hose
30. Hose
35. Elbow
53. Screw

C7 - C9 - C11 - C15 604.13.235 - 09/2002

4 SECTION 10 - ENGINE - CHAPTER 1

TORQUE SPECIFICATIONS
Fastening hardware Screws, nuts Thread Torque
Flange (12), engine............................................................... 47.......................M10 ....................................44 Nm
Hydraulic pump, flange (12)............................................... 112*.......................M14 ..................................118 Nm
Rear bracket (5, 6) ................................................................ 51.......................M12 ....................................75 Nm
Bracket (1, 2), engine............................................................ 51.......................M12 ....................................75 Nm
Engine bracket (1, 2, 5, 6) with rubberized metal pieces)..... 64.......................M12 ....................................75 Nm
Cooling fan............................................................................ 48.......................M10 ....................................44 Nm
* Secure with Loctite No. 577

SPECIAL TOOLS
No1. Hood support 10-1-01 (For holding hood in raised
position)

ND080080 3
No2. Pin for securing hydraulic hood lifting cylinders

ND080220 4
No3. Hook 10-1-03 (For lifting hood)

ND101778 5

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 10 - ENGINE - CHAPTER 1 5

No4. Engine support 10-1-02 (For supporting engine)

ND080183 6

C7 - C9 - C11 - C15 604.13.235 - 09/2002

6 SECTION 10 - ENGINE - CHAPTER 1

REMOVAL
1. Lift the hood and support it with the No.1 tools, in
lifted position.
No.2
2. Disconnect the electrical wiring.
3. Remove the pins from ends of the hydraulic cylin-
ders and secure with an appropriate pin No.2.

No.1 No.1

CD01C013 7
4. Install the No.3 tool support.

No.3

CD01C014 8
5. Remove the hinges.

CD01C015 9

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 10 - ENGINE - CHAPTER 1 7

6. Attach the No.3 tool hooks.

No.3

CD01C016 10
7. Set the hood to one side, using the No.3 tools.

No.3

CD01C017 11
8. Loosen the filler cap and drain the coolant.

CD01C018 12
9. Remove the hoses (27, 30) and rubber elbow (35).
Remove the hoses to the hydraulic cooler and plug
the openings. 35

27
30

CD01C019 13

C7 - C9 - C11 - C15 604.13.235 - 09/2002

8 SECTION 10 - ENGINE - CHAPTER 1

10. Remove the supports (8).

CD01C020 14
11. Loosen the screws (53).

53

CD01C021 15
12. Use hooks to lift the radiator and set it on one side.

CD01C022 16
13. Remove the hydraulic reservoir cover.

CD01C023 17

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 10 - ENGINE - CHAPTER 1 9

14. Remove the suction hose (A) running from the

hydraulic reservoir to the steering pump.

CD01C024 18
15. Disconnect the hoses to the steering pump, and
plug the orifices.

CD01C025 19
16. Loosen the turbo clamp screw (23).

23 23

CD01C026 20
17. Remove the four screws (28) on the air filter sup-
port.
18. Disconnect the wiring to the filter detector and set
the filter to one side.

28

CD01C027 21

C7 - C9 - C11 - C15 604.13.235 - 09/2002

10 SECTION 10 - ENGINE - CHAPTER 1

19. Loosen the clamp (3) on the exhaust pipe.

20. Remove the exhaust pipe support screws (31). Set
the muffler to one side.
21. Plug the openings. 31

CD01C028 22
22. Label mask and disconnect all wires - ground
strap, starter wires, alternator wires, water temper-
ature and oil pressure detectors, tachometer, and
injection pump solenoid.

CD01C029 23
23. Disconnect the throttle cable (29).

29

CD01C030 24
24. Disconnect the fuel intake and overflow.

CD01C031 25

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 10 - ENGINE - CHAPTER 1 11

25. Lift the cab using the hydraulic lift, then use a suita-
ble lifting device to relieve the piston of the lifting
hydraulic cylinder using tool No.1.

CD01C032 26
26. Remove the screws. Set the rubber partition to one
side.

CD01C033 27
27. Remove the screws (47, 56) from the flange (12).

47
56 12

CD01C034 28
28. Suspend the pump, using a suitable lifting device.

CD01C035 29

C7 - C9 - C11 - C15 604.13.235 - 09/2002

12 SECTION 10 - ENGINE - CHAPTER 1

29. Slide out the drive coupling (86) support.

86

CD01C036 30
30. Remove the nuts from the front engine muffler
blocks (64).

64

CD01C037 31
31. Remove the nuts from the rear muffler blocks (64).

64

CD01C038 32
32. Suspend the engine from a suitable lifting device
with hooks.
33. Remove and set to one side on support No.4.

CD01C039 33

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 10 - ENGINE - CHAPTER 1 13

INSTALLATION
Procede in the reverse order from that of removal, refer
to the hardware torques specified in the “Torque specifi-
cations”.

ACCELERATOR CABLE ASSEMBLY

REMOVAL AND INSTALLATION
Disconnect the accelerator cable.

CD01D155 34
Dismantle and raise the instrument panel, loosen the
nuts (22) and remove the accelerator (8), bracket (3) and
cover (13). When the cable is to be replaced, release the
clamp on the fuel injection pump lever.
Grease the new cable. Adjust the clearance between the
cover (13) and the switch when installing the cable 1 mm
assembly. Set the position of the cover (13) for the vibra-
22
tor switch to engage at engine maximum speeds.

Speed value 13
8
C7 - C9 2200 + 30 rpm 3
C11 - C15 2250 + 30 rpm CD01D156 35

C7 - C9 - C11 - C15 604.13.235 - 09/2002

14 SECTION 10 - ENGINE - CHAPTER 1

NOTES

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 21 - TRANSMISSION - CHAPTER 1 1

SECTION 21 - TRANSMISSION

Chapter 1 - Hydraulic motor

CONTENTS
Section 62731 Description Page
Description ..................................................................................................... 2
Specifications ................................................................................................. 3
Torque specifications .................................................................................... 3
Disassembly ................................................................................................... 3
Reconditioning and replacement ................................................................. 5
Assembly ........................................................................................................ 8

C7 - C9 - C11 - C15 604.13.235 - 09/2002

2 SECTION 21 - TRANSMISSION - CHAPTER 1

DESCRIPTION

13
27
14
24
26 20
25
18
16
22 23 17
2
4 5 10
1

29
21
35
3 8
34
11 15
12 33
10
9 32
28
7
31
6 30

36
37

CS02B591 1
1. Screw 23. Screw
2. Screw 24. Feedback fork
3. End cover 25. Setting lug
4. Gasket 26. Servo-piston
5. Pin 27. Glide ring
6. Valve segment 28. Sensor ring
7. Distribution plate 29. Shaft
8. Pin 30. Spring seat
9. Cylinder block 31. Spring
10. Support pin 32. Pin
11. Synchronizing shaft 33. Bearing
12. Rollers 34. Bearing
13. Screw 35. Retaining nut
14. Bearing housing 36. Piston
15. Main housing 37. Piston ring
16. O-ring
17. O-ring
18. Spacer ring
20. Shaft assembly
21. Plug
22. Screw

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 21 - TRANSMISSION - CHAPTER 1 3

SPECIFICATIONS

Type 51C060 51C080

Machine C7 - C9 (rear and front) C15 (front)
C11 (rear and front)
C15 (rear)

Maximum displacement 60 cm3 80.7 cm3

Minimum displacement 12 cm3 16.1 cm3
Max. continuous flow 216 l/min 250 l/min
Max. continuous power 336 kW 403 kW
Weight 28 kg 32 kg

TORQUE SPECIFICATIONS

Type 51C060 51C080

End cap to motor 66 Nm 78 Nm
Bearing housing to main housing 32 Nm 32 Nm
End cover plug (21) 54 Nm 95 Nm

Cone point set screw (23) 5 Nm 5 Nm

Lock screw (22) 8.5 Nm 19 Nm

DISASSEMBLY
1. Remove the screws (1), (2) retaining the end cover
(3) assembly to the motor housing.
7
2. Remove the end cover (3) assembly gasket (4) and 6
alignment pins (5).
8 1
3. Remove the internal motor parts as shown.
4. Remove the valve segment (6). 9
NOTE: The orientation of the segment in relation to the 10
end cover (3) and housing.
5. Remove the distribution plate (7) and the pins (8). 12

NOTE: Orientation of the pins (8). 11 2

6. Remove the cylinder block (9). 10 3
7. Remove the support pin (10). 4
8. Remove the synchronizing shaft (11) and rollers 5
(12).
9. Remove the shaft seal.
CS01D553 2

C7 - C9 - C11 - C15 604.13.235 - 09/2002

4 SECTION 21 - TRANSMISSION - CHAPTER 1

10. Remove the screws (13) attaching the bearing

housing (14) to the main housing (15). Separate 13 19
the bearing housing from the main housing (15).
11. Remove the O-ring (16), (17). 14
12. Remove the spacer ring (18). Note the orientation.
13. Press the shaft assembly (20) out of the bearing 17
housing, taking care to not damage the shaft, pis- 16
ton sockets, and speed sensor ring (if installed).
14. The inner retaining ring (19) for the shaft seal car- 20
rier may be removed from the bearing housing at
this time.
18

15

CS01D554 3
15. Remove the end cover plug (21).
22 24b 24a
16. Remove the lock screws (22) and cone point set
screws (23). 26
21
For 51C060 frame size
17. Remove the feedback fork (24a) through the hole 23
in the end cover (3). Remove the setting lug (25a)
from inside the end cover (3). 27
23
For 51C080 frame size 22
18. Remove the feedback fork (24b) setting lug from 25a
inside the end cover (3).
For all frame sizes
CS02B573 4
19. Remove the servo-piston (26) from the end cover
(3).
20. Inspect the glide ring (27) for damage or wear.
21. Remove the glide ring (27) from the servo-piston
(26) if replacement is required.

22. Inspect the servo-piston (26) bore in the end cover

(3) for damage or wear.

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 21 - TRANSMISSION - CHAPTER 1 5

RECONDITIONING AND REPLACEMENT

SHAFT ASSEMBLY
1. The optional magnetic speed sensor ring (28) is
pressed on to a machined surface of the output shaft
flange.

! WARNING !
Do not damage the magnetic speed sensor ring
(28).

2. Check the seal area of the shaft (29) and the out-
put splines for damage or wear.
3. Inspect the synchronizing shaft insert (10) and the
36
spring seat (30) for wear. The internal spring (31) 10
must not be damaged. These parts are retained by
three hardened steel pins (32) pressed into blind
holes in the synchronizing shaft insert (10), and are
not serviced separately.
28
4. Inspect shaft bearings (33) and (34) for wear and 32
roughness. Check that the bearing retaining nut
(35) is firmly staked to the output shaft, and that no 30
noticeable looseness is detected in the bearings.
31
NOTE: If the bearing adjustment for used bearings is
incorrect or if used bearings must be replaced, a com- 29
plete shaft assembly including pistons and new bear-
ings must be installed.
33
5. Check the piston assemblies (36) for damage or
wear. It is normal for the piston sockets to be
retained in the output shaft by an interference 35
press fit.
34

NOTE: If a piston (or pistons) must be replaced, a com-

plete shaft assembly including piston and new bearings CS01D556 5
must be installed.
6. The replacement output shaft assembly includes
pistons and bearings.

C7 - C9 - C11 - C15 604.13.235 - 09/2002

6 SECTION 21 - TRANSMISSION - CHAPTER 1

PISTON RINGS
1. A small pair of retaining ring pliers may facilitate the
removal of the piston rings (37) from the pistons.
37
2. Install new piston rings on the pistons.

NOTE: When installing new spherical piston rings,

make sure the spherical surface conforms to the shape
of the piston.
3. A radial identification mark is provided on the
“outer” side of the piston rings.
4. The ends of each piston ring must not overlap each
other.

37

CS01D557 6

DISTRIBUTION PLATE, VALVE SEGMENT AND CYLINDER BLOCK

1. Inspect the running (bronze) surface of the distribu-
tion plate (7) for damage and excessive wear. The
sealing surfaces must be free of scratches and
7
nicks. The locating pin holes must not be worn.
Replace the distribution plate if damaged or worn.

CS01D558 7
2. Inspect the valve segment (6) for damage or wear
on the sealing surfaces. Inspect the spindle for
wear.
6

CS01D559 8

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 21 - TRANSMISSION - CHAPTER 1 7

3. Check that the spindle is located correctly in the

valve segment by measuring distance “A”. If this
dimension is not within the range shown in the
accompanying chart, it indicates that the spindle
has moved in the valve segment and the assembly
must be replaced. “A”

Frame size Distance “A” mm

51C060 27.5 to 27.7
51C080 32.6 to 32.8
4. Inspect the cylinder block assembly for wear or
damage. The piston bores must be smooth. The
bearing plate surface must be free from scratches 9
CS01D560
or nicks, and the holes for the distribution plate
locating pins must not be worn.
5. Inspect the cylinder block bearing. If it requires
replacement, remove the bearing using a suitable
extractor.

NOTE: Do not damage the distribution plate surface of

the cylinder block.

CS01D561 10
6. Press the new bearing into the cylinder block using
a suitable press pin. Press the bearing into the cyl- “B” “A”
inder block until it is located the proper distance
below the distribution plate surface, as indicated by
distance “A” in the following table:

Distance “B”
Frame size Distance “A” mm (in)
mm
51C060 3.0 to 3.5 (0.12 to 0.14) 25.97 (1.022)
51C080 11.5 to 12 (0.45 to 0.47) 27.97 (1.101)

CS01D562 11

C7 - C9 - C11 - C15 604.13.235 - 09/2002

8 SECTION 21 - TRANSMISSION - CHAPTER 1

ASSEMBLY
1. Install a new glide ring (27) on the servo-piston
(26). 22 24a 24b

2. Lubricate with hydraulic oil, the glide ring (27) and

install the servo-piston (26) into the end cover (3). 23 23 21
The end of the servo-piston (26) with the glide ring
(27) is located opposite the multi-function block/ 27
control mounting surface of the end cover (3).
For 51C060 frame size: 22
3. Install the setting lug (25a) into the servo-piston 22
(26) from inside of end cover (3). 22
4. Install the cone point set screw (23) so that its point 3
enters the groove in the setting lug and torque CS02B573 12
(Torque: 5 Nm).
5. Install and torque the lock screw (22) (Torque:
8.5 Nm).
6. Install the feedback fork (24a) into the servo-piston
(26) through the hole in the end cover (3). The con-
tact pads on the fork must face forward the multi-
function block/control end cover (3). Install the
cone point so that it enters the groove in the feed
back fork (24). Do not tighten the set screw at this
time.
7. Install and torque the end cover plug (21) (Torque:
54 Nm).
For 51C080 frame size:
8. Install the feedback fork/setting lug (24b) into the
servo-piston (26) through the hole in the end cover
(3). The offset of the fork must be located away
from the multi-function block/control end of the end
cap (3).
9. Install the cone point set screw (23) so that its point
enters the groove in the feedback fork/setting lug.
Do not tighten the set screw at this time.
10. Install and torque the end cover plug (21). (Torque:
95 Nm).

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 21 - TRANSMISSION - CHAPTER 1 9

For all frame sizes

11. The feedback fork (51C060) or feedback fork/set-
ting lug (51C080) must be positioned perpendicu-
larly to the setting piston for proper control spring
operation.
22

23
51C060 frame size
CS01D563 13
12. A 26.9 mm diameter rod with the end machined
perpendicularly to its axis may be inserted through
the valve sleeve bore in the end cover (3) to align
the fork while tightening the cone point set screw
(23). Torque the cone point set screw (23) to 5 Nm.
13. After torquing the cone point set screw, install and
torque the lock screw (22) (Torque: 8.5 Nm for
51C060 frame; 19 Nm for 51C080). 22

23
51C080
CS01D564 14
14. The inner retaining ring (19) for the shaft seal car-
rier may be installed in the bearing housing at this
time.
15. Press shaft assembly (20) into bearing housing
(14). 15
NOTE: Do not damage the piston sockets or shaft seal 17
surface.
16
16. Install spacer ring (18). The end of the spacer with
the larger inside diameter is installed next to the
inner shaft bearing cup.
18
17. Install O-rings (16) and (17) and install main hous-
ing (15).
20
18. Install and torque screws (13). Torque: 32 Nm for
51C060 and 51C080 frame.

14
13
19
CS01D565 15

C7 - C9 - C11 - C15 604.13.235 - 09/2002

10 SECTION 21 - TRANSMISSION - CHAPTER 1

19. Install the first synchronizing shaft support pin (10)

into the recess in the cylinder block (9).
20. Install the synchronizing shaft roller (12) on the 9
journals of the synchronizing shaft (11) and retain
with grease. 10
21. The recess on each roller (12) must be positioned
to face the center line of the synchronizing shaft 12
(11).
22. Position each roller (12) with its outside edge flush 11
with the end of the synchronizing shaft (11) journal.
23. Install the second synchronizing shaft support pin 10
(10) into the motor shaft assembly and retain with
grease.
24. Install the synchronizing shaft (11) and rollers (12)
into the motor shaft. The cylinder block (9) end of
the shaft is larger than the motor shaft end on all
frame sizes.
25. The rollers (12) must enter the races in the motor
shaft insert, and the recess in the end of the syn-
chronizing shaft (11) must engage the support pin.
26. Tip and rotate the synchronizing shaft (11) in all
directions to check for binding. The synchronizing CS01D566 16
shaft rollers (12) must move freely in the races in
the motor shaft insert.
27. Position the motor shaft in the housing as shown in Position the motor
the accompanying illustration. Tip the three pistons shaft as shown
closest to the minimum angle stop out toward the prior to installing
housing. the cylinder block
28. With the synchronizing shaft (11) supported in the
motor shaft, install the cylinder block (9) and its
synchronizing shaft (11) support pin (10) onto the
pistons and synchronizing shaft (11). The cylinder
block (9) must be positioned so the synchronizing
shaft rollers (12) will enter their races in the block,
while each piston enters its corresponding bore in
the block.
Cylinder block not installed
CS01D568 17
29. A brass rod may be inserted through the cylinder
block (9) kidney-shaped apertures to guide the pis- 9
ton into position. Start with the six pistons closest 10
to “Lowest” part of the end cap mounting surface.
30. After the six pistons enter their bores, tilt the cylin-
der block (9) so the synchronizing shaft rollers (12)
enter their races in the cylinder block (9) and the
12
support pin enters its recess in the synchronizing
shaft (11). 11
31. Lift the cylinder block (9) slightly and guide the
remaining three pistons into their bores.

CS01D569 18

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 21 - TRANSMISSION - CHAPTER 1 11

32. Once the last piston is in position, check the posi-

tion of the rollers closest to the minimum angle
stop. Maintain an inward force on the cylinder block
(9) and carefully push it toward the “highest” part of
the end cover mounting surface and check that all
of the synchronizing shaft rollers (12) are in posi-
tion.
33. If the cylinder block (9) is properly installed, there
will be very little rotational free play between the
block and the motor shaft.
34. Install the bearing plate locating pins (8) into the
cylinder block (9). The longer end of each shoul-
dered pin is installed into the block. 1
35. Install the distribution plate (7) on the cylinder block 3
(9), with its steel side facing toward the block.
Lubricate the bronze side of the plate with hydraulic
oil.
36. Install the end cover alignment pins (5) and gasket 5
(4). Carefully locate the cylinder block (9) in the 2
approximate center of the housing opening. 7
8
NOTE: Do not allow the pistons or synchronizing shaft
rollers to fall out of position. 9 6
37. Install the valve segment (6) into the end cover (3)
so the setting lug in the servo-piston engages and
retain with heavy grease. The hole in the end of the
4
segment should be installed opposite the minimum
displacement adjustment screw. Locate the valve
segment and servo-piston in the approximate
center of their travel.
38. Install the end cover (3) assembly and valve seg-
ment (6). The segment spindle must engage the
bearing in the cylinder block (9). CS01D572 19

NOTE: Do not allow the pistons or synchronizing shaft

rollers (12) to fall out of position.
39. Install the screws (1) and (2) fastening the end
cover assembly to the motor. The screws must be
installed in their proper locations to ensure ade-
quate thread engagement. The internal spring (in
the motor shaft) should hold the end cover (3) a
short distance away from the housing.

C7 - C9 - C11 - C15 604.13.235 - 09/2002

12 SECTION 21 - TRANSMISSION - CHAPTER 1

40. Tighten the screws by hand in a “double X” pattern

while rotating the motor shaft to ensure proper 7/15
3/11 2/10
5/13
positioning of the synchronizing shaft rollers.

NOTE: Do not force the end cover (3) into position on

the housing.
41. Place the end cover (3) is in position on the hous-
ing. 3

6/14 1/9 4/12 8/16

CS02B575 20
42. When the end cover (3) is in position, torque the
screws in a “double X” pattern.

Frame size Torque Nm

51C060 66
51C080 78
9
43. Rotate the motor shaft and check for “play”
between the shaft and cylinder block (9). Any play
indicates that the synchronizing shaft rollers (12) 12
are not installed correctly. Recheck the end cover
(3) screw torque.
44. Reinstall the minimum angle servo-cover, control
spring (if used). Four-way valve spool and sleeve (if 3
used) and control and multi-function block (if used).

CS01D553 21

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 21 - TRANSMISSION - CHAPTER 2 1

SECTION 21 - TRANSMISSION

Chapter 2 - Travel reduction gear

CONTENTS
Section 62737 Description Page
Specification ................................................................................................... 1
Torque specifications .................................................................................... 2
Special tools ................................................................................................... 2
Exploded view of travel brake ...................................................................... 6
Disassembly and assembly .......................................................................... 7
Brake test ........................................................................................................ 9
Exploded view .............................................................................................. 10
Disassembly and assembly ........................................................................ 11

SPECIFICATION

FRONT REDUCTION GEAR

C7 - C9 C11 C15
Type Trasmital 706 C2H 43,8 709C3B31C75H1GQU26 710 C3 B H2
Total ratio T.B.A. 1:75 T.B.A.
Nominal torque T.B.A. daNm 3000 daNm T.B.A. daNm
Max. output torque T.B.A. daNm 3500 daNm T.B.A. daNm
Oil quantity T.B.A. l 3.4 l ± 10% T.B.A. l
Oil type T.B.A. SAE 80W90 T.B.A.
Technical braking data
Braking torque T.B.A. daNm 40 daNm T.B.A. daNm
Min. opening pressure T.B.A. bar 12 bar T.B.A. bar
Max. opening pressure T.B.A. bar 50 bar T.B.A. bar

C7 - C9 - C11 - C15 604.13.235 - 09/2002

2 SECTION 21 - TRANSMISSION - CHAPTER 2

REAR REDUCTION GEAR

C7 - C9 C11 - C15
Type transmital 706 C2H10C26H1HR 7072B24C33H1HQ
Total ratio 1:26 1:33
Nominal torque T.B.A. daNm T.B.A. daNm
Max. output torque T.B.A. daNm 695 daNm
Oil quantity T.B.A. l 2 l ±10%
Oil type T.B.A. SAE 80W90
Technical braking data
Braking torque 45 daNm 40 daNm
Min. opening pressure T.B.A. bar 14 bar
Max. opening pressure T.B.A. bar 50 bar
TORQUE SPECIFICATIONS
Cover (20)/flanged hub (18) retaining screws...............................................................................................50 Nm
Reduction gear cover (2) retaining screws ...................................................................................................75 Nm
Third stage satellite carrier (13) retaining screws .......................................................................................585 Nm
Hydraulic motor retaining screws................................................................................................................215 Nm

SPECIAL TOOLS

TOOLS REQUIRED
Loctite 243
Torque wrench (40 to 200 Nm) - (120 to 600 Nm)

TOOLS TO BE MADE
No 1. Brake spring compression tools
350 mm
= =

20 mm
=

40 mm
=

M14x1.5 Ø 22
= =
285 mm

Ø15
3X45°
3

30 mm
20 mm

Ø 75 M14x1.5 L = 130 mm
Ø 90

CM95K023 1

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 21 - TRANSMISSION - CHAPTER 2 3

No 2. Tool for assembling bearing surface seals

12 mm
24 mm

Ø 318 mm
3 - 0.1 mm

0
Ø 347.5 + 0.1 mm
0
0

0
Ø 351.5 - 0.1 mm
0
0

Ø 358 mm

PDH0016 2

No 3. Tools for assembling reduction gear housing complete with bearings

B Ø 260 mm A
Ø 238 mm

-0.1 - 0.004
Ø 220 -0.2 mm

16 mm
200 mm

Ø 100 mm

-0.1 - 0.004
Ø 120 -0.2 mm

PDH0018 3 PDH0017 4

NOTE: Tools A and B are necessary when replacing the reduction gear bearings.

C7 - C9 - C11 - C15 604.13.235 - 09/2002

4 SECTION 21 - TRANSMISSION - CHAPTER 2

No 4. Tool for extracting third stage satellite shaft

Ø 10 mm
70 mm

M12

25 mm
10 mm
95 mm

Ø 70 mm A-A
295 mm

Ø 70 mm

Ø 50 mm
Ø 30.5 mm
Ø12 mm

Ø 70 mm M10 x 55
15 mm

M10 M10
15 mm
35 mm

Ø 14 mm
M8

Ø10.5 M12 4 mm
mm A A
20 mm

M8 x 40

PDH0014 5

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 21 - TRANSMISSION - CHAPTER 2 5

No 5. Tool for removing and installing third stage satellites, complete with bearings

Ø 55 mm

8 mm

52.5 mm

10 mm

Ø 22 mm

Ø 40 mm

CS01E514 6

C7 - C9 - C11 - C15 604.13.235 - 09/2002

6 SECTION 21 - TRANSMISSION - CHAPTER 2

EXPLODED VIEW OF TRAVEL BRAKE

22
23
24

25

27
29
30
31

26
28

CS01E512 7
22. Coupling sleeve 27. O-ring
23. Friction disc 28. Brake piston
24. Steel disc 29. Spring
25. Spacer 30. Spring retainer
26. O-ring 31. Snap ring

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 21 - TRANSMISSION - CHAPTER 2 7

Before performing any service work on the machine,

the following steps must be carried out in the order
shown:
- Park the machine on hard flat ground.
- Stop the engine.

DISASSEMBLY AND ASSEMBLY

1. Place a receptacle with a minimum capacity of
5 litres (1.3 US gal) under the reduction gear cover.
Remove the drain plug and drain all the oil. Then
clean and inspect threads, and install and tighten
the plug.

NOTE: When assembling, fill the reduction gear hous-

ing with the recommended oil (see "Specifications").
See the Operator’s Manual for the procedure.
2. Remove the travel motor.
3. Remove the brake line union and discard the seal.
4. Install the brake spring compression tool (see
"Tools to be made"). Tighten up to the snap ring
(31). Remove the snap ring (31) from its housing
using snap ring pliers.

31

CS01E506 8
5. Remove the spring retainer (30).

30

CD01E021 9

C7 - C9 - C11 - C15 604.13.235 - 09/2002

8 SECTION 21 - TRANSMISSION - CHAPTER 2

6. Remove the springs (29) from their seats in the

brake piston (28).

NOTE: When assembling, place the springs (29) as

shown in the photograph.

29

28

CD01E022 10
7. Extract the brake piston (28).
28
NOTE: When assembling the brake piston (28) and the 25
spacer (25), proceed as follows: assemble the spacer
(25) with the new seals (27) on the brake piston (28),
making sure it is pointing the right way. 27

PDH0011 11
8. Extract the spacer (25) and discard the O-ring (26).

NOTE: When assembling the spacer, see note in Step

7.

25

CD01E023 12
9. Remove the travel motor/reduction gear coupling
sleeve (22).

22

CD01E024 13

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 21 - TRANSMISSION - CHAPTER 2 9

10. Remove the brake disc pack (23, 24).

24

23

CD01E025 14

NOTE: When assembling, the friction discs (23) and

the steel discs (24) must be installed alternately as
shown in the drawing. Before mounting the hydraulic
motor, use a depth gauge to measure the axial distance 23
from the input side of the flanged hub to the coupling
sleeve.
Axial dimension (d) = 93.2 - 94 mm.

NOTE: When assembling, proceed in the reverse order

from that of disassembly. Replace all seals with new d
24
seals which have been lubricated prior to installation.

CS01E507 15

BRAKE TEST
If the brake has been disassembled then a brake func-
tion test is needed before putting it into operation.
Proceed as follows:
- Connect the pressure pilot line with the pressure
gauge to the brake release port with the flow valve shut.
- Open the flow valve and release the brake with the
pilot pressure of 50 bar.
- Shut the flow valve and keep the brake released for 3
minutes.

NOTE: If the pressure drops, the gearbox reassembly

is not correct, or the seals are damaged; in this case the
seals have to be replaced.

CS01E508 16

C7 - C9 - C11 - C15 604.13.235 - 09/2002

10 SECTION 21 - TRANSMISSION - CHAPTER 2

EXPLODED VIEW
11.
12. 1
13. 5
14. 2
8
9
10
12
13
14 4
15
3
16 6
7
17
18
19 11
20
21

CS01E513 17

1. Screw 12. Screw

2. Cover 13. Third stage satellite carrier
3. Washer 14. Stud
4. Drain plug 15. Housing with bearing assembly
5. O-ring 16. Half seal
6. Friction disc 17. Brake stop
7. Central shaft 18. Hub
8. First stage satellite carrier 19. O-ring
9. Sun gear 20. Cover
10. Second stage satellite carrier 21. Screw
11. Sun gear

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 21 - TRANSMISSION - CHAPTER 2 11

DISASSEMBLY AND ASSEMBLY

1. Unscrew and remove the 3 flat headed screws
(21), which fix the cover (20) to the flanged hub
(18). Remove the cover (20) and the O-ring (19)
from its seat in the flanged hub (18), see figure 17.

NOTE: When assembling, tighten the screws to a

torque of 50 Nm (36.9 lb.ft). 21
20
! WARNING !
In case of oil leakage, it may be necessary to check
and eventually replace the half-seal (16), which
means both the steel rings and the O-rings.
CD01E026 18
2. Use a screwdriver to remove the first half-seal (16)
from the cover (20).
3. Use a screwdriver to remove the second half-seal
(16) from the flanged hub (18).

CD01E027 19
4. Place the reduction gear in the position shown.
Mark the position of the cover (2) in relation to the
reduction gear housing. Remove the cover (2)
retaining screws (1) and remove the cover (2).

NOTE: When assembling, tighten the screws to a

torque of 75 Nm. Check the position of the coupling
sleeve.

1
2

C08120 20

C7 - C9 - C11 - C15 604.13.235 - 09/2002

12 SECTION 21 - TRANSMISSION - CHAPTER 2

5. Remove the cover (2) and discard the O-ring (5).

5

2
C08114 21
6. Remove the central shaft (7).

C08112 22
7. Remove the first stage satellite carrier (8).

C08110 23
8. Remove the sun gear (9).

CD01E028 24

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 21 - TRANSMISSION - CHAPTER 2 13

9. Remove the second stage satellite carries (10).

CD01E029 25
10. Remove the sun gear (11).

C08104 26
11. Disassemble the four third stage satellite carrier
retaining screws (12).

NOTE: When assembling, tighten the screws to a

torque of 585 Nm and apply Loctite 243.

12

C08410 27
12. Extract the third stage satellite carrier (13) from the
reduction gear housing, using an extractor.

NOTE: When assembling, carefully install the third

stage satellite carrier using a press.

PDH0355 28

C7 - C9 - C11 - C15 604.13.235 - 09/2002

14 SECTION 21 - TRANSMISSION - CHAPTER 2

13. Extract the four third stage satellite shaft and studs
(14) using a slide hammer extractor. See "Tools to
be made".

NOTE: When assembling, install the four satellite

shafts and the four studs (14) using a press.

PDH0359 29
14. Remove the brake stop (17).

17

C08016 30
15. Extract the reduction gear body from the reduction
gear housing (15) using a press. Take precautions
to prevent the ball bearings escaping from their
housing. Remove the upper bearing inner race.

PDH0379 31
16. Extract the reduction gear body lower bearing inner
race, using an extractor.

PDH0361 32

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 21 - TRANSMISSION - CHAPTER 2 15

NOTE: For assembly:

- Fit the lower bearings (d), into the gearbox housing
(15) holding the inner race (c) with spacers (b) and
(tool 3B). d
- Remove the spacer (b).
- Install the upper bearings (e).
- Install the inner race (f).
- Place the flanged hub (18) inside the gearbox hous-
ing (15). Using a press and a metal plate, push the
flanged hub (18) inside, see figure 17. c

3B
b

CS01E509 33

3B
b

CS01E510 34
- Screw the safety bushing (Tool No.5) in one of the
four holes in the flanged hub (18) using the socket
head screw (12) and turn the gearbox housing flange
hub group (15, 18) upside down, see figure 17.
- At the end of the above Step, remove the safety
bushing.

NOTE: When assembling the reduction gear proceed

in the reverse order from that of disassembly. Replace
all seals with new seals which have been lubricated
prior to use. Clean and inspect all sealing surfaces, all
Tool No.5
bearing sealing surfaces. Clean, inspect and lubricate
all threaded ports.

12
CS01E511 35

C7 - C9 - C11 - C15 604.13.235 - 09/2002

16 SECTION 21 - TRANSMISSION - CHAPTER 2

NOTES

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 29 - HYDROSTATIC DRIVE - CHAPTER 1 1

SECTION 29 - HYDROSTATIC DRIVE

Chapter 1 - Pumps - Drive coupling

CONTENTS
Section 62721 Description Page
Specifications ................................................................................................. 1
Torque specifications ..................................................................................... 1
Description ..................................................................................................... 2
Special tools ................................................................................................... 3
Removal of pumps, Drive coupling ............................................................... 3
Drive coupling ................................................................................................. 7

SPECIFICATIONS

TORQUE SPECIFICATIONS
Fastening hardware Screws Nuts Thread Torque
Flange (12), engine............................................................... 47.......................M10 .....................................44Nm
Flange (12), engine............................................................... 56.......................M16 .............................. T.B.A Nm
Flange (12), hydraulic pump ................................................. 55............................... .............................. T.B.A Nm
Hydraulic pump ......................................................................11............................... .............................. T.B.A Nm
“A” segments......................................................................... T1............................... ...........................155/165 Nm
Coupling segments (86)/hydraulic pump .............................. T2............................... ..................................120 Nm

C7 - C9 - C11 - C15 604.13.235 - 09/2002

2 SECTION 29 - HYDROSTATIC DRIVE - CHAPTER 1

DESCRIPTION

86
56
47
55

11

12

CS01D545 1
11. Screw
12. Flange
47. Screw M10 x 35
55. Screw
56. Screw M16 x 20
86. Hydraulic drive coupling

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 29 - HYDROSTATIC DRIVE - CHAPTER 1 3

SPECIAL TOOLS
No1. Cab support 29-1-01 (For holding cab in raised
position)

ND080078 2
No2. Centering plate 29-1-02 (for centering coupling
clutch)

ND080155 3

REMOVAL OF PUMPS, CLUTCH

1. Lift the cab using the hydraulic lift, then use a suita-
ble lifting device and tool No.1 to relieve the piston
of the hydraulic lifting cylinder.

CD01C032 4
2. Remove the screws (53). Set the rubber partition to
one slide.
53

CD01C033 5

C7 - C9 - C11 - C15 604.13.235 - 09/2002

4 SECTION 29 - HYDROSTATIC DRIVE - CHAPTER 1

3. Remove the hose clamps.

CD01C097 6
4. Disconnect all hydraulic hoses from the hydraulic
pumps.
5. Plug the hydraulic pump openings and the hose
ends.

CD01C137 7
6. Disconnect the wires to the hydraulic pumps.

CD01C098 8
7. Suspend the vibration hydraulic pump using a suit-
able lifting device and remove the screws (11)
holding both hydraulic pumps, see figure 1.
8. Slide out the pump and set it on one side.

CD01C099 9

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 29 - HYDROSTATIC DRIVE - CHAPTER 1 5

9. Suspend the hydraulic travel pump, using a suita-

ble lifting device.

CD01C106 10
10. Remove the screws (47), (56) from the flange (12).

56
47

12

CD01C034 11
11. Separate the drive coupling (86).
12. Set the hydraulic pump with the flange to one side.

86

CD01C036 12
13. Remove the (T1) screws from the (A) segments.

T1

CD01C109 13

C7 - C9 - C11 - C15 604.13.235 - 09/2002

6 SECTION 29 - HYDROSTATIC DRIVE - CHAPTER 1

14. Remove the screws (T2), and remove the coupling

segment (86) from the hydraulic drive shaft.

T2

86

CD01C110 14
15. Remove the screws (55) and the flange (12).

55

12

CD01C111 15

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 29 - HYDROSTATIC DRIVE - CHAPTER 1 7

DRIVE COUPLING

ASSEMBLING THE DRIVE COUPLING

1. Install the (A) segments on the flywheel. Center the
segments using tool No. 2. Lubricate the screws No.2
(T1) under the head with grease and tighten them
to the torque specified in the table. Check their
position after tightening. T1
A
A A

CD01C112 16
2. Fix flange (12) on the flange of the hydraulic travel
drive shaft and coupling (86) with the (B) seg-
ments. Tighten the (T2) bolts of coupling (86) to the
torque indicated in the table.
12

T2

86 B

CD01C110 17
3. When installing the coupling (86), determine the
axial clearance between the flywheel face and the
elastic element of the drive coupling. Measure the
distance “a” as illustrated, from the face of the fly-
wheel housing.
a

CD01C113 18

C7 - C9 - C11 - C15 604.13.235 - 09/2002

8 SECTION 29 - HYDROSTATIC DRIVE - CHAPTER 1

4. Measure distance “b” as illustrated, from the elastic

element face to the seating area of flange (12). 12

b
B
T1

CD01C114 19
5. Difference in the distances a - b = 1 to 3 mm

NOTE: Colored (e.g. blue color) material is deposited

on the thread of the supplied countersunk hexagonal
screws. It includes a film of adhesive and prevents them
from coming loose. The hardening time for such adhe-
sive material after tightening the screws is 4 to 5 hours
at an ambient temperature of 20°C. The machine must
not be used during until this period of time. Full harden-
12
ing is obtained after 24 hours. At higher temperatures
the hardening can be faster, e.g. 15 minutes at 70°C 47.71 b
(heating with a hot air fan). Temperature stability of the a
bolts is between -80 and 90°C and they can be used
three times maximum. The adhesive material is some- CS01C506 20
times eliminated and it is deposited between the head
of the screw and the segment. This is not a defect,
rather an advantage - both areas will adhere to each
other better. If original supplied screws are not availa-
ble, both the bored thread and screw must be carefully
degreased and a layer of Loctite or Omnifit should be
applied to them.
Spring washers must not be used
The tandem hydraulic pumps including the connection
of hydraulic hoses and electrical wiring should be
installed using a suitable lifting device, following the pro-
cedure in reverse order.

Hardware torque
T1 bolt: 155 to 165 Nm
T2 bolt: 120 Nm

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 1

SECTION 35 - HYDRAULIC SYSTEM

Chapter 1 - Hydraulic cylinders for Cab and Hood

CONTENTS
Section 82060 Description Page
Torque specifications .................................................................................... 1
Description ..................................................................................................... 2
Special tools ................................................................................................... 3
Hood hydraulic cylinders .............................................................................. 5
Cab hydraulic cylinder .................................................................................. 7
Hydraulic cylinders ........................................................................................ 7

TORQUE SPECIFICATIONS
Gland (10) M45 x 1.5 ....................................................................................................................................80 Nm
Piston rod (4), nut (8) M14 x 1 ......................................................................................................................50 Nm

C7 - C9 - C11 - C15 604.13.235 - 09/2002

2 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1

DESCRIPTION

3 11

11
17

4
4

CS01D585 1
1. Bracket
3. Hydraulic locking device
4. Pin
11. Hydraulic cylinder
17. Hydraulic locking device

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 3

SPECIAL TOOLS
No.1 Hood support 10-1-01 (For holding hood in raised
position)

ND080080 2
No.2 Pin for securing hood lifting hydraulic cylinders

ND080220 3
No.3 Hook 10-1-03 (For lifting hood)

ND101778 4
No.4 Cab support 29-1-01 (For holding cab in raised
position)

ND080078 5

C7 - C9 - C11 - C15 604.13.235 - 09/2002

4 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1

No.5 Spanner 35-1-02 (For gland disassembly)

Spanner 35-1-03 (For gland disassembly)

ND101784 - ND101785 6
No.6 Hydraulic cylinder piston installer 35-1-01 (For
assembling piston in hydraulic cylinder)

ND101783 7
No.7 Gland wrench 35-1-04 (For gland disassembly)

ND107335 8
No.8 Gland wrench 35-1-05 (For gland disassembly)

ND107337 9

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 5

HOOD HYDRAULIC CYLINDERS

REMOVAL
1. Lift the hood and support it with the No.1 tools in
lifted position.
No.2
2. Disconnect electrical wiring.
3. Remove the pins from ends of hydraulic cylinders
and secure with an appropriate pin No. 2.

No.1 No.1

CD01C013 10
4. Install the No. 3 hood lowering support tool.

No.3

CD01C014 11
5. Remove the hinges.

CD01C015 12

C7 - C9 - C11 - C15 604.13.235 - 09/2002

6 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1

6. Attach the No. 3 tool hooks.

No.3

CD01C016 13
7. Remove the hood, using theNo. 3 tools and a hoist
and set it to one dide.

No.3

CD01C017 14
8. Place a receptacle underneath the cylinder to be
removed (11). Disconnect the hoses and plug
them. Remove the shims and press out the pins (4)
from the piston ends. Use lifting equipment to
remove and remove the hydraulic locking device
11
(17). 11

17

4
4 17

CD01C153 15

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 7

CAB HYDRAULIC CYLINDER

Lift the cab, support it using tool No. 4, place a recepta-
cle under the hydraulic cylinder, press piston rod in the
cylinder, remove the hydraulic cylinder with the bracket
(1) from the machine, press out the pin (4) and remove 4 3
the hydraulic locking device (3).

CD01C154 16

HYDRAULIC CYLINDERS

REPLACEMENT OF SEALS
Place a receptacle under the hydraulic cylinder and
plug the openings. Drill out the safety pin from the face
of the front gland (10) or bend back the gland (10) 8 5 4 10
safety lug, depending on the type of the hydraulic cylin-
der. Using wrench No. 5 (depending on the type of
hydraulic cylinder) to remove the gland (10), slide out
the piston rod (4) with the piston (5) and remove the nut
(8) and the piston. Slide off the gland (10).

CS01C509 17
Soak new seals in oil before replacing them.
1. Seal
1 6 6 2 3
2. Packing
3. Wiper ring
4. Carrier ring
5. Ring
6. Ring

5 4

CS01C509 18

C7 - C9 - C11 - C15 604.13.235 - 09/2002

8 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1

ASSEMBLY
Sliding surfaces should be lubricated, check that the
surface of the piston rod is not damaged. New seals
should be straightened out. Wait at least 15 minutes
before complete assembly of the hydraulic cylinder after
new seals have been installed. For assembling piston
rod in the piston in the cylinder use tool No. 6 and No. 7
or No. 8. Threads to be tightened to the torque indi-
cated in the table.

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2 1

SECTION 35 - HYDRAULIC SYSTEM

Chapter 2 - Vibration Motor

CONTENTS
Section 82071 Description Page
Specifications ................................................................................................. 1
Torque specifications .................................................................................... 1
Description ..................................................................................................... 2
Disassembly ................................................................................................... 3
Assembly ........................................................................................................ 8
Supply pressure relief valve adjustment ................................................... 12

SPECIFICATIONS

C7 - C9 C11 C15
Motor 90M042 90M055

Maximum displacement 42 cm3 55 cm3

Rated speed at max. disp. 4200 rpm 3900 rpm
Maximum speed at max. disp. 4600 rpm 4250 rpm

Theoretical torque at max. disp. 0.67 Nm/bar 0.88 Nm/bar

Maximum flow at max. disp. 193 l/min 254 l/min
Maximum continuous power 155 kW (208 hp) 187 kW (251 hp)

Weight 17 kg 26 kg

TORQUE SPECIFICATIONS

Motor 90M042 90M055

Large screws T.B.A. Nm 122 Nm
Housing, end cover gasket
Small screws T.B.A. Nm 41 Nm
Retainer plate 16 Nm 16 Nm

C7 - C9 - C11 - C15 604.13.235 - 09/2002

2 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2

DESCRIPTION

2 1

5 4
6
23
3
7

24
26 14
11
16

12 13
23

10 19
15 27
21 28
9

26
8
25
18 20
21
17 22
CS01D551 1
1. Screw 15. Distribution plate
2. Retainer plate 16. Pin
3. Packing ring 17. Screw
4. Retaining ring 18. Screw
5. Bearing 19. Guide sleeve
6. Shaft 20. Spool
7. Housing 21. Spring
8. End cover 22. Plug
9. Gasket 23. Plug
10. Retaining tube 24. Piston retainer
11. Slipper guide 25. Plug
12. Cylinder block 26. Plug
13. Piston 27. Plug
14. Swash plate 28. Relief valve
29. Key

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2 3

DISASSEMBLY
1. Position the motor with the shaft facing up.
2. Remove the three or four screws holding the
retainer plate and seal carrier. Remove the retainer
plate.

NOTE: Certain early production units use a single

retainer plate and seal carrier assembly.

CD01D129 2
3. After removing the screws, the spring force on the
shaft may move the seal carrier out of its bore by
approximately 5 mm. If the seal carrier does not
move from its bore after removing the screws, pry it
from its bore as shown and/or lightly tap the end of
the shaft with a soft mallet.
4. Remove the O-ring from the seal carrier.
5. Place the seal carrier and seal under a press and
press out the old seal.
6. Using an 17 mm wrench, remove the hex plugs
and O-rings from both sides of the valve.
7. Remove the springs, shoulder washers and relief CD01D130 3
valve shuttle spool. Note the orientation of the
washers. Remove the relief valve spool.
8. Inspect the parts for damage or contamination.

NOTE: Early production motors used a small diameter

shuttle valve spool. Late production motors use a larger
diameter spool.
9. Remove the shim type adjustable supply pressure
relief valve plug with a 22 mm hex wrench. Before
removing the screw type adjustable relief valve
plug, mark the plug, lock nut and housing so as to
be able to maintain the original adjustment when
assembling.

CD01D133 4

C7 - C9 - C11 - C15 604.13.235 - 09/2002

4 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2

10. Remove the shaft and bearing assembly from the

housing. The bearing outside diameter is a slip fit in
the housing bore.

CD01D100 5
11. Remove the retaining ring and press the shaft out
of the bearing.
12. Place the motor on the work surface with the end
cover up. Using a 19 mm and a 13 mm hex wrench
for 90M055 motors, loosen the screws which fas-
ten the end cover to the housing. Remove the five
longer screws.
13. Place the motor on its end cover. Remove the two
shorter screws holding the end cover to housing.
14. Lift the housing off the end cover.

NOTE: The dowel pins and gasket should remain with

the end cover. The thrust plate should remain in the CD01D101 6
housing. The piston assemblies should remain with the
other internal parts on the end cover, but may stick to
the thrust plate.
15. Place the housing on the end cover face with soft
material between end of the housing and the work
surface, so the thrust plate will not be damaged
when it is freed from the housing.
16. Entering through the shaft end of the housing,
using a brass rod, carefully apply a force to the
inside diameter of the thrust plate and disengage it
from the housing.

CD01D102 7

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2 5

17. Remove the end cover gasket from the end cover.
18. Remove the retaining tube with the slipper guide
and piston assemblies from the end cover and cyl-
inder block.

CD01D103 8
19. Remove the slipper guide and piston assemblies
from the retaining tube.

CD01D105 9
20. Remove the slipper guide bearing.
21. Remove the slipper guide bearing shim (if used).

CD01D106 10
22. Remove the cylinder block from the end cover.

CD01D107 11

C7 - C9 - C11 - C15 604.13.235 - 09/2002

6 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2

23. Remove the distribution plate and alignment pins

from the end cover.
24. Remove the piston assemblies from the slipper
guide.

CD01D108 12

RECONDITIONING AND REPLACEMENT OF PARTS

1. After disassembly all parts should be thoroughly
cleaned in a suitable solvent. Replace the shaft seal
and all gaskets.
2. Inspect all parts for damage, nicks, or abnormal
wear patterns. Replace all parts showing signs of
unusual or excessive wear or discoloration.
3. If the end cover journal bearing needs replacement
(as evidenced by large amounts of the metal back
of the bearing being visible through the plastic
bearing material), remove the bearing with a suita-
ble puller. Do not damage the distribution plate sur-
face of the end cover.

CD01D070 13

CD01D071 14

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2 7

4. Lightly lubricate the steel backing of a new journal

bearing. Press the journal bearing into the end
Split line in bearing
cover using a suitable drive. The split line in the
MUST be located within
bearing must be located as shown in the accompa- arcs shown, but NOT in
nying illustrations, but NOT in line with the drain line with drain groove in
groove in the end cover bearing bore. bearing bore

Drain Groove
Early production
CS01D531 15

Split line in bearing

MUST be located within
arcs shown, opposite
drain groove in
bearing bore

Drain Groove
Later production
CS01D532 16
5. When installed correctly, the bearing will be flush to
0.50 mm below the distribution plate surface of the
end cover.

CD01D072 17
6. If a new journal bearing was installed, the bearing
must be sized with the appropriate arbor to assure
the minimum bore diameter is met. Carefully press
the sizing arbor into the bearing to size it.

! WARNING !
The arbors are precision finished to size the journal
bearings without damaging them. Damaged arbors
must be replaced. Do not attempt to use the drive
shaft in place of an arbor. Bearing damage and
shortened life will result from inadequate clearance.

CD01D073 18

C7 - C9 - C11 - C15 604.13.235 - 09/2002

8 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2

7. Compress the cylinder block spring and remove

the spiral retaining ring, retainer, spring and spring
seat. Reassemble in the reverse order.

CS01D539 19

ASSEMBLY
1. Clean and lightly oil parts prior to assembly of the
motor. Be sure to torque all threaded parts to the
recommended torque specification.

! WARNING !
Most parts have critical, high tolerance surfaces.
Caution must be exercised to prevent damage to
these surfaces during assembly. Protect exposed
surfaces, openings, and ports from damage and for-
eign material.

2. Place the end cover on the work surface with the

distribution plate surface up. Install the alignment
pins in the end cover.

NOTE: The size of the alignment pins has changed on

certain frame size motors. Refer to the appropriate
Parts Manual for more information.

CD01D109 20

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2 9

3. Install the distribution plate on the end cover with

the locating notches positioned over the alignment
pins.

NOTE: This is a bi-directional distribution plate, with no

directional arrow cut-outs.

CD01D108 21
4. Lubricate the end cover journal bearing and the
cylinder block and distribution plate running sur-
faces. Position the cylinder block assembly on the
distribution plate.

CD01D110 22
5. Place the retaining tube over the cylinder block with
the fluted end adjacent to the end cover.

NOTE: If a new housing is to be installed, a new tube

must also be used.

CD01D112 23
6. Position the straight fingers on the retaining tube
over the distribution plate locating tabs and in the
clearance holes in the end cover. The long side of
the tube must be positioned on the same side as
the end cover gauge ports.

CD01D113 24

C7 - C9 - C11 - C15 604.13.235 - 09/2002

10 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2

7. Place the slipper guide retainer shim on the retain-

ing tube. The tab with the “V” notch must be posi-
tioned in the tube cutout which is located 45°
counter-clockwise from the longest side of the tube
assembly.
8. Assemble the bronze slipper guide bearing on top
of the slipper guide retainer shim, positioning the
tab with the “V” notch in the same position as noted
above.

NOTE: Certain frame sizes use a one-piece slipper

guide retainer shim and bearing. The one-piece shim
and bearing is installed with the tab with the “V” notch
positioned as noted above, and with its bronze side fac- CD01D114 25
ing “up” (toward the slipper guide).
9. Assemble the piston assemblies into the slipper
guide.
10. Lubricate the pistons and cylinder block bores.
Install the assembled slipper guide and pistons into
the cylinder block by inserting the pistons into the
cylinder block bores.The pistons and bores are not
selectively matched, therefore no specific piston
and bore matching is required.

CD01D115 26
11. Place a new gasket on the end cover. The beaded
side of the gasket must be positioned away from
the end cover.

CD01D103 27

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2 11

12. Lubricate the slipper running surfaces, then place

the thrust plate on the slipper faces. The side of the
thrust plate with the chamfered edge must be posi-
tioned away from the slipper faces. The slots in the
thrust plate must be positioned over the tabs on the
retaining tube.

CD01D116 28
13. Place the housing over the assembled internal
parts, with the deep end of the cavity in the housing
mated to the long side of the retaining tube. The
housing will engage the alignment pins in the end
cap. When the housing is properly installed, the
retaining tube will hold the housing away from the
end cover (approximately 0.75 mm (0.03 in)).
14. Install and hand tighten the two short end cover
screws holding the end cover to the housing. Place
the motor on the work surface with the end cover
up, and install the remaining end cover screws.
Tighten the end cover screws evenly to the torque
indicated in the accompanying table.
CD01D117 29
Torque
Frame size Large screws Small screws
Nm Nm
90M042 T.B.A. Nm T.B.A. Nm
90M055 122 41
15. Position the motor on its end cover. Using caution
to prevent damage to the sealing surface, press
the roller bearing onto the drive shaft. (For units
with a three piece bearing, press the inner race
onto the shaft, then install the outer race/cage
assembly and the special washer). Mount the
bearing retaining ring on the shaft.

C7 - C9 - C11 - C15 604.13.235 - 09/2002

12 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2

16. Install the shaft and bearing assembly through

front of housing, aligning the shaft spline with the
cylinder block spline. Continue to lower the shaft
into the unit and carefully align the end of the shaft
with the end cap journal bearing. Then lower the
shaft and bearing assembly into position.
17. Rotate the shaft by hand. The rotating assembly
should turn freely. If it does not rotate freely, the
motor must be disassembled and the problem cor-
rected.
18. Rotate the motor shaft with a torque wrench to
assure correct assembly. When properly assem-
bled, the torque required to turn the shaft (after CD01D120 30
“break-away”) should be within the ranges shown
in the accompanying table.

Torque required to turn shaft (Fixed Motor at 17°)

Nm
Frame Size Minimum Maximum
90M042 T.B.A. Nm T.B.A. Nm
90M055 6.8 13.6
19. Assemble the seal carrier and seal over the shaft
and into the housing bore. Install the retainer plate.
20. Install the screws and torque to 16 Nm.
21. Install the valve spool in the end cover, then install
the shoulder washers (with shoulders facing “out”)
and springs on each end of the spool. Install the
hex plugs with O-rings, and torque to 41 Nm,
22. For shim adjustable valves, install the plug and
torque to 68 Nm.

SUPPLY PRESSURE RELIEF VALVE ADJUSTMENT

1. To measure motor supply pressure, install a 50 bar
pressure gauge in the motor supply pressure
gauge port (M3). Also install a gauge 50 bar to
measure the case pressure. Operate the system
with the pump in stroke (forward or reverse) when
measuring motor supply pressure.
M3

CD01D121 31

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2 13

2. The following table shows acceptable motor supply

pressures for some nominal supply pressure relief
valve settings (see model code). These pressures
are based on a reservoir temperature of 49°C.
They relate to case pressure and are valid for a sin-
gle motor system. 90M055 NC 0 N
Nominal charge
Motor charge pressure 8 N 0 C6 W 00 pressure setting
Model code setting (Acceptable range)
NNN 00 00 24
(±1.4 bar)
10 bar 8.1 bar
18 bar 16.1 bar c.g. “24” = 24 bar
20 bar 18.1 bar 32
24 bar 22.1 bar
28 bar 26.1 bar
30 bar 30.0 bar
3. Early production Series 90 motors are equipped
with a shim adjustable supply pressure relief valve.
Shim kits are available as service items. Adjust-
ment of the supply pressure is accomplished by
removing the plug (7/8 inch hex) and changing the
shim thickness behind the spring. The plug for this
type of supply pressure relief port should be
torqued to 68 Nm.

CD01D122 33
Later production Series 90 motors are equipped
with an external screw adjustable supply pressure
relief valve. Adjustment of charge pressure is
accomplished by loosening the lock nut (with a 1-1/
16 inch hex, and turning the adjustment plug with a
large screwdriver or a 1/2 inch hex wrench. Clock-
wise rotation of the plug increases the setting, and
counter-clockwise rotation decreases the setting
(at a rate of approximately 3.4 bar per turn). The
lock nut for this type charge relief supply pressure
should be torqued to 52 Nm.

CD01D123 34

4. Once the desired supply pressure setting is

obtained, remove the gauges.

C7 - C9 - C11 - C15 604.13.235 - 09/2002

14 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2

NOTES

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3 1

SECTION 35 - HYDRAULIC SYSTEM

Chapter 3 - Hydraulic circuit

CONTENTS
Section 80000 Description Page
Hydraulic installation ..................................................................................... 2
Functional description ................................................................................... 2
Travel without activation ............................................................................... 3
Travel activated, moving forward ................................................................. 4
The multi-function valve ................................................................................ 5
The idler-wheel lock-block on the flow divider ........................................... 6
ASC valve ....................................................................................................... 7
Vibration hydraulics ...................................................................................... 8
Vibration without activation .......................................................................... 8
Vibration activated ....................................................................................... 10
Steering hydraulics ...................................................................................... 12
Steering without activation ......................................................................... 13
Steering to the right ..................................................................................... 14
Lifting hydraulics ......................................................................................... 15
Lifting of the cab or hood ............................................................................ 16
Lowering the cab and hood ........................................................................ 17
Reservoir hydraulics ................................................................................... 18
Hydraulic reservoir ...................................................................................... 18
Discharging of closed circuits .................................................................... 19
Brake release - emergency towing ............................................................. 20
Test points .................................................................................................... 21
Releasing transmission and wheel hydraulic motor brakes .................... 23
Hydraulic diagram ........................................................................................ 26

C7 - C9 - C11 - C15 604.13.235 - 09/2002

2 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3

HYDRAULIC INSTALLATION
The hydraulic system controls all main functions of the DIAGRAM OF THE HYDRAULIC CIRCUITS
machine. The power unit drives hydraulic pumps and • Hydraulic circuit connections are identical in both cir-
supplies hydraulic pressure to the hydraulic motors cuits. Differences are only in the types of the pumps
which convert this form of energy into kinetic energy. and hydraulic motors used.
Distribution through the machine is assured by pipes
and pressure hoses. Other controlling, regulating and • The C7 machines uses a xxx pump and xxx hydraulic
safety components are installed in the circuit. motor for vibration.
• The C11 machine uses a 90r042 pump and 90m042
• Electro-valve, safety and control valves, hydrostatic
locks. hydraulic motor for vibration.
• The C15 machine uses a 90r055 pump and 90m055
The hydraulic system consists of the following circuits: hydraulic motor for vibration.
• Hydraulics for travel and hydraulic regulators • Further differences are in the adjustment of a control
• Hydraulics for vibration pressure by-pass valve in the body of the vibration
pump, where on the C7 - C9 its pressure is 28 bar,
• Hydraulics for control and on the C11, 42 bar, and on the C15, 28 bar. Con-
trol pressure setting in the bodies of travel pumps is
• Hydraulics for lifting
identical in both cases - 22 bar. Operation of the indi-
• Hydraulic reservoir vidual closed circuits or their parts is described in
detail in the following part.

FUNCTIONAL DESCRIPTION
TRAVEL HYDRAULICS THE ASC LOCK
In the main closed circuit, the hydraulic oil flows through Supplied as optional equipment, it acts as an electroni-
the pressure hoses between the axial piston variable cally controlled and hydraulically driven inter-axle lock
hydraulic pump and two high-speed hydraulic motors system, responding to immediate state of wheel traction
with wheel drive speed reduction gears and one conditions and for loading the machine on a truck.
hydraulic motor with the roller drive unit attached. Value It consists of the SAUER S1X ASC control unit (micro-
of the pump flow is given by the drive speed and dis- processor), the SAUER proportional valve and the
placement of the pump. The displacement is deter- SAUER machine inclination sensor. The system com-
mined by the angle of the pump inclined plate, ponents are the speed sensors built in the hydraulic
controlled hydraulically by the servo-valve which is con- motors for the wheels and roller. The roller hydraulic
trolled electrically; direction of the pressurized oil flow motor includes an electro-valve which controls volume
(travel direction) changes according to the degree of of the oil flowing through. The control unit evaluates the
inclination of the oscillation plate from its zero position. speed of the roller and wheels by means of the sensors
Part of the roller drive hydraulic motor is an electrically located in the hydraulic motors for the wheels and roller.
controlled control valve for selecting a second speed In the event of different wheel speeds or a difference
range (travel). If the ASC inter-axle differential lock in between the wheels and the roller speed caused by
ON, the control valve is controlled by the SAUER S1X insufficient traction, it will make the necessary torque
control unit with pulses. In this case, it results in continu- adjustment.
ous inclination of the block with little change in piston Control of the torque on the roller hydraulic motor is per-
displacement and torque, depending on adhesion. formed electronically from the S1X control unit by
On the left side of the travel pump, a valve (flow divider) means of the electro-magnetic pulse valve which con-
is mounted, operating as a wheel hydraulic regulator. tinuously controls the inclination of the hydraulic motor
block.
On the right side of the travel pump there is a two-way
proportional valve (SAUER), electronically controlled by Control of the torque on the wheel (axle) hydraulic
the SAUER S1X unit, which is the part of the ASC inter- motors is obtained by pressure reduction in the SAUER
axle lock. two-way proportional valve, which is controlled by the
Furthermore, the hydraulic circuit is fitted with a filtration S1X unit.
block with a 0.0004 in pressure filter, a two speed con-
trol valve for the wheels, and control valve of a parking
brake for the roller and the wheels.
In addition, on the steering block there is the oil pres-
sure filter restriction sensor.

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3 3

TRAVEL WITHOUT ACTIVATION

A
CI01E502 1
Oil reaches the filtration block from the steering pump, and then proceeds to the travel pump. The fluid passes into the
pump casing via the 22 bar safety valve (A).
From there, pressure reaches the multi-function valves, and then the closed circuit of the proportioning devices, ASC,
hydraulic motors, and eventually power steering.
The travel casing drains into the vibration casing.
Brakes have been applied to the machine; brakes in the reduction gears are not under pressure.

C7 - C9 - C11 - C15 604.13.235 - 09/2002

4 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3

TRAVEL ACTIVATED, MOVING FORWARD

CI01E503 2
Oil flows through the steering filtration block to the travel pump. Part of the fluid goes via the 22 bar safety valve (A)
into the pump housing, the other part flows through the safety valve spool in the closed circuit of the drum hydraulic
motor into the drum hydraulic motor housing. From there the fluid goes into the housing on the hydraulic motors of the
wheels and thereon into the hydraulic reservoir.
The fluid flows from the travel pump housing into the vibration pump casing.
The electro-valve control is activated, the power valve deflects the spool of the power cylinder control to its extreme
position, and the cylinder tilts the plate of the travel pump.
The brake control valve solenoids are activated and release pressurized oil into the brakes in the travel reduction
gears. The brakes of the machine have been released.
The pressurized oil flows from the pump to the inputs of the travel hydraulic motors and moves the machine forward.

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3 5

THE MULTI-FUNCTION VALVE

CI01E504 3
The multi-function valve contains
- Short-circuit valve position 1.
- One-way valve for supplying the closed circuit position
2.
- Safety valve consisting of a control and an excess-flow
valve. The excess-flow valve allows for the flow of the
superfluous fluid from the pressure circuit into the oppo-
site circuit. The control valve controls the excess-flow
valve and equalizes pressures in the pump power cylin-
der when the safety pressure has been reached, i.e., it
returns the plate to zero position (relieves load on the
engine).
CD01D145 4

CD01D146 5

C7 - C9 - C11 - C15 604.13.235 - 09/2002

6 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3

THE IDLER WHEEL LOCK BLOCK ON THE FLOW DIVIDER

CI01E505 6
The block contains: Situation: the machine is moving forward, the left wheel
is spinning from loss of traction.
1. Safety valves (A) 450 bar integrated with a one-
way valve for emergency increase of the supply Increase of flow through the hydraulics of the left wheel
pressure in the circuit between the flow divider and originates changes in control pressures on the faces of
the hydraulic motor on the wheel. the flow divider spool. The spool restricts the increased
flow and maintains minimal difference between the
2. The 1.8 mm orifice providing the stability of the sys-
speed of both wheels until traction conditions have
tem of the idler-wheel lock during tight turns.
changed and equalized wheel speed.
3. Two-way flow divider with automatic set-up of con-
trol logic in line with the direction of the flow.

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3 7

ASC VALVE

CI01E506 7
ASC is a dual, electrically powered restriction valve. The hydraulic motor revolution sensor signals the differ-
The operating part is a gate controlled by an electro- ence in wheel speed to the micro-processor. The micro-
valve. processor sends signals to the electro-valve, which
allows the pressurized fluid to the gate. The gate
Situation: the left wheel is spinning in forward travel.
restricts the flow to the hydraulic motor turning at higher
revolutions until both wheel speeds are equal.

C7 - C9 - C11 - C15 604.13.235 - 09/2002

8 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3

VIBRATION HYDRAULICS
Inside the main closed circuit, the hydraulic oil flows The hydraulic motor drives the vibration exciters, which
between the axial piston variable hydraulic pump and turn mutually after the hydraulic motor changes its
the fixed speed hydraulic motor. direction of rotation and this results in a change of the
eccentric moment value (amplitude). Simultaneously,
Value of the hydraulic pump flow is given by its drive
flow volume. i.e. frequency changes, too. Hydraulic oil is
speed and displacement. Direction of the pressurized
re-injected into the system by the steering hydraulic
oil flow changes depending on the inclination of the tilt-
pump with the oil coming through the oil filters from the
ing plate from the zero position. The inclination is
hydraulic reservoir.
adjusted by the hydraulically controlled servo-valve.

VIBRATION WITHOUT ACTIVATION

Oil arrives from the steering pump into the filtration The pressure reaches both lines of the closed circuit via
block and from there flows to the vibration pump and the multi-function valve.
safety valve, which is not functioning. The 28 bar for the
C7 and C9 and 42 bar for C11 - C15 supply pressure is
provided by the pressure valve in the travel pump.

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3 9

Model: C7 - C9

CS02B607 8
Model: C11 - C15

CI0E507 9

C7 - C9 - C11 - C15 604.13.235 - 09/2002

10 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3

VIBRATION ACTIVATED
From the steering pump oil reaches the filtration block
and from there goes to the vibration pump and the con-
trol valve. The solenoid is powered, slides the control
valve over to the extreme position and the pressure
reaches one side of the pump power cylinder. The plate
is positioned in an extreme position. The pump delivers
maximum output to one line of the closed circuit
(marked in red) at a pressure which is determined by
the load on the hydraulic motor. The opposite return line
of the closed circuit is under supply pressure (marked in
green), and drains via the drain valve of the hydraulic
motor into the hydraulic motor casing and from there to
the reservoir (marked in blue).

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3 11

Model: C7 - C9

CS02B608 10
Model: C11 - C15

CI01E508 11

C7 - C9 - C11 - C15 604.13.235 - 09/2002

12 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3

STEERING HYDRAULICS
The steering hydraulics consists of the servo-steering The servo-steering parts are:
unit, as controlled by the steering wheel, where the
• Double shock valve: this is a variably adjustable, dou-
source of pressurized oil is a fixed gear-type hydraulic
ble acting linear limiting valve. It operates in conjunc-
pump that takes in oil from the hydraulic tank and sends
tion with a suction valve.
it under pressure into the servo-steering. There the oil
flow splits depending on the steering wheel turning • Suction valve: this is a safety valve which protects
direction. From the servo-steering, the oil flow enters against the occurrence of pulses. In conditions of une-
into straight-line hydraulic steering cylinders. Effect of venness, it compensates with hydraulic liquid in order
pressure on the piston results in motion of a piston rod, to avoid development of pressure loss on the opposite
the heads of which are connected to the linkage. The side of the hydraulic cylinder in the event of increasing
piston rod gives the reciprocating linear motion and pressure at the shock valve.
turns the frame with the roller.
• Non-return valve: this avoids the effects of pressure
1. Gear pump pulses on the gear pump.
This converts mechanical energy into pressurized • Pressure control valve: this is a directly controlled, lim-
hydraulic oil. The pump features teeth with a special iting valve variably adjustable from 5 MPa to 16 MPa.
shape for improved efficiency and minimized pulsation.
Quality, performance and reliability are ensured by the
2. Servo-steering high manufacturing tolerances of individual compo-
nents. Because of the repair quality this entails, repair
While turning the steering wheel, the volume of the
by replacement of the individual components is consid-
hydraulic supply oil flowing through the servo-steering
ered as uneconomical. In the event of some parts mal-
into the linear cylinder is proportional, depending on the
functioning, the entire system (valve block) is to be
steering wheel turning angle. The one-way shock valve
replaced.
built inside the valve block compensates the adverse
effect of pressure pulses on the steering wheel during In the case of overall wear, the steering assembly is to
travel. be replaced with a new one.

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3 13

STEERING WITHOUT ACTIVATION

Model: C7 - C9

CS02B605 12
Model: C11 - C15

CI01E509 13
Oil is pumped from the tank by the steering pump and oil under pressure passes through the open center of the
power steering into the filtration block.
Devices for feeding closed circuits are connected to the output of the filtration block.

C7 - C9 - C11 - C15 604.13.235 - 09/2002

14 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3

STEERING TO THE RIGHT

Model: C7 - C9

CS02B606 14
Model: C11 - C15

CI01E510 15
Oil is pumped from the oil reservoir by the steering pump and flows under pressure through the open valve in the
power steering, through the hydraulic motor and into the steering cylinders.
Under the effect of the movement of the steering cylinders, oil passes from the opposite openings of the filtration block
on to the power steering and feeds the closed circuits.

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3 15

LIFTING HYDRAULICS
Lifting and lowering the hood and the operator’s com- The manual hydraulic pump, an emergency source of
partment for access to the engine, the hydraulic and pressure energy for driving the linear cylinders, is of the
vibration traveling pump and other components for double acting piston type, with rectilinear reversible
inspection, maintenance and repairs is performed by motion from the manual lever.
two hydraulic cylinders for the hood and one for the
Maintenance of the entire system consits of lubrication
operator’s compartment.
of the lever system pins to meet machine operation
The power source is a small unit consisting of a 24V conditions but at a minimum once per year and of keep-
electric motor, a pump and a suction filter. In addition, ing the pins and piston rods in a clean state.
an electro-valve is included in the circuit for varying the
The hydraulic locking device is built into the block fixed
pressurized oil flow.
on the linear hydraulic cylinders.
The pump is not repairable. If pump function defects are
The hydraulic locking device totally seals off the hydrau-
noticed during operation, resulting in excessive prolon-
lic circuit under pressure. It ensures the constant posi-
gation of the time necessary for lifting the hood and the
tion of the lifted hood and operator’s compartment and
operator’s platform and insufficient pressure being
protection against descending slowly over time or
developed by the pump, the pump has to be replaced
against failure of the hydraulic circuit (sudden leakage
by a new one.
of the fluid).
In the event of failure, a manual hydraulic pump can be
substituted in the circuit. During its usage, the electro-
valve distributor can be controlled mechanically, thereby
avoiding dependence on the machines electrical circuit.
The lifted hood and operator’s compartment are locked
hydraulically by load holding valves in the raised posi-
tion, which also protects against accidental oil losses
from the system.

C7 - C9 - C11 - C15 604.13.235 - 09/2002

16 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3

LIFTING OF THE CAB OR HOOD

CI01E511 16
The electric pump pumps oil from the hydraulic reservoir and sends it to the control valves.
By activating the cab (hood) lifting solenoid the valve opens and the pressurized oil flows through the show locking
device for the cab (hood) lifting cylinder and into the hydraulic cylinder. The cab (hood) lifts up.

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3 17

LOWERING THE CAB AND HOOD

CI01E512 17
The electric pump, pumps oil from the hydraulic reservoir and sends it to the control valves.
The cab (hood) solenoid is activated, the valve opens and pressurized oil flows to the hydraulic cylinder. At the same
time, the hydraulic locking device is released and the cab (hood) overrides the restriction valve in the hydraulic locking
device to return to its original position.
In case of an emergency, such as a defect in the wiring or battery, it is possible to lower or lift the cab or hood by
means of a manual pump and manual mouvement of the control valve spools to the correct position.

C7 - C9 - C11 - C15 604.13.235 - 09/2002

18 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3

RESERVOIR HYDRAULICS
The oil reservoir is welded out of the steel plates, and The hydraulic circuit is supplied from the hydraulic res-
bolted to the upper frame portion. ervoir by the steering hydraulic pump via the suction
strainer and the filtering block.
Inside the reservoir, the following parts are to be found:
a suction strainer with a cleaning lid, a level indicator In the return line of the hydraulic system, the reservoir is
and a sight gauge. provided with a siphon to avoid oil leakage during
repairs of the machine; only for repair (replacing) of the
In the reservoir bottom are a discharge valve, a hydrau-
steering hydraulic pump is it necessary to disconnect
lic block, and an electric pump for the operator’s com-
the screw coupling of the suction hose on the reservoir.
partment and the hood raising and lowering.
The discharge valve is opened by turning it to the left;
The hydraulic block consists of the cooler by-pass
flow can be controlled by manually turning the valve.
valve, the thermostatic valve and the oil temperature
The valve end position is locked against falling out. Do
sensor. The by-pass valve protects the hydraulic pump
not loosen it forcibly across the end position; it can
cases against high pressure. The thermostatic valve
result in damage to the valve and the closing part falling
maintains optimum temperature of hydraulic oil in range
out.
of 55°C to 70°C. At low hydraulic oil temperature, the
cooler is by passed.

HYDRAULIC RESERVOIR

5 bar (72psi)

CI01E513 18
The hydraulic reservoir consists of Oil flows to the reservoir block and through the cooler
into the reservoir. As long as the oil temperature is
1. Suction strainer
lower than 40°C, the thermostat lets the fluid flow into
2. Filler neck with a venting and air filter cap the reservoir without cooling. With increased tempera-
ture the thermostat restricts gradually the flow and at
3. Level indicator
55°C the entire flow of the return line goes through the
4. A block mounted to the bottom of the reservoir, with oil cooler.
a thermostat, hydraulic oil temperature sensor, and
a 5 bar by-pass valve for pump casing overload
protection.
5. A hydraulic oil drain valve is screwed to the bottom
on the other side and an electrical pump for lifting
and folding of the cab and hood

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3 19

DISCHARGING OF CLOSED CIRCUITS

Model: C7 - C9

CS02B604 19
Model: C11 - C15

CI01E514 20
Situation: The machine is moving forward and the drum • Discharging of the closed travel circuit: the fluid drains
is vibrating. into the drum drive hydraulic motor, from there in par-
allel into the housing of the wheel drive and eventually
Supply pressure arriving from the filtration block is sep-
into the reservoir.
arated into three basic flow passages.
• Discharging of the closed vibration circuit: the fluid
• Flow through the supply pressure safety valve in the
drains into the vibration hydraulic motor housing and
travel pump, which discharges the travel pump hous-
eventually into the reservoir.
ing, from there into the vibration pump housing and
eventually into the reservoir.

C7 - C9 - C11 - C15 604.13.235 - 09/2002

20 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3

BRAKE RELEASE - EMERGENCY TOWING

CI01E515 21
Pressure produced by the manual pump reaches the fil- By disconnecting the quick-couplers and connecting
tration block, the 17 bar safety valve (A) and the electro- them to drain, the circuit is isolated from the machine
valve. brake release function and returns to its original func-
tion as a feedback circuit.
When the electro-valve spool moves the pressure
reaches the individual brakes of the "Trasmital" gear-
boxes.

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3 21

TEST POINTS
In order to allow easy diagnostics of the hydraulic cir-
cuits, the test points are grouped in a bank and pro-
vided with quick-couplers for easy and drip-free
connection of the measuring instruments (M16 x 2 1
thread).
2
Model: C7 - C9

C7 - C9
3
Pressure in the reverse travel 4
350 bar*
circuit (1)
5
Pressure in the forward travel
350 bar*
circuit (2)
CD02B031 22
Pressure in the vibration circuit I
350 bar
(3)
6
Pressure in the vibration circuit II
350 bar
(4)
Pressure in the steering circuit (5) 180 bar**
Pressure feed pump (6) 24 bar***

* This value will be raised by the forced feed pressure,

i.e. by up to 30 bar.
** Total pressure in the steering circuit (forced feed
pressure plus flow-through losses).
*** Value at idle speed; at higher speed, it is higher,
maximum 30 bar. CD02B032 23

C7 - C9 - C11 - C15 604.13.235 - 09/2002

22 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3

Model: C11 - C15

Pressure in the reverse travel circuit (1): 420 bar*
2 1
Pressure in the forward travel circuit (2): 420 bar*
Pressure in the vibration circuit I (3): 400 bar
Pressure in the vibration circuit II (4): 400 bar 3
Pressure in the steering circuit (5): 190 bar**
Pressure feed pump (6): 22 bar*** 4
Pilot pressure (M7)
5

CD01E008 23
* This value will be raised by the forced feed pressure,
i.e. by up to 30 bar.
** Total pressure in the steering circuit (forced feed
pressure plus flow-through losses)
*** Value at idle speed; at higher speed, it is higher,
maximum 30 bar.
M7

CD01E009 24

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3 23

RELEASING TRANSMISSION AND WHEEL HYDRAULIC MOTOR BRAKES

Model: C11 - C15
Release the hose (4) and quick-coupling (3) from the
clamp (5). 5
3
4

CD01D151 25
Disconnect the quick-coupling (2) from the hose (1)
from the pressure filter to the hydraulic reservoir.
2

CD01D152 26
Connect the hose (4) to the manual hydraulic pump
using the quick-coupling (2) and (3) on the hose (1).

4
2 3
1
CD01D153 27

C7 - C9 - C11 - C15 604.13.235 - 09/2002

24 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3

Model: C7 - C9
Release hose (4) by quick-coupler (3) in clamp (5).
Disconnect hose (1) from pressure filter to hydraulic 1
tank in quick-coupler (2).

5 3 4
CD02B032 28
Connect quick-coupler (3) on hose (4) to manual
hydraulic generator with quick-coupler (2) in hose (1). 4

2
3

CD02B033 29

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3 25

For all models

Next, short circuit the hydraulic travel circuit. The travel
hydraulic pump has two multi-purpose main relief
valves. Unscrew middle portions (1) of the valves (hex
27 mm) three turns counter-clockwise.
Then turn the starter switch key to position I.
Insert the control lever into the manual hydraulic pump
and pump until the brake warning light goes off.
The machine now has its brakes released for towing.

NOTE: Because of leakage, the pressure in the brake 1

line may drop during towing. Should the brake warning 1
light come on during towing, pressure should be
renewed. CD01D150 30

NOTE: During towing check that the brakes do not heat

up due to insufficient release. When the hydraulic motor
brakes have been released and the travel hydraulic cir-
cuit has been short-circuited, the working, emergency,
or parking brakes cannot be applied. All brakes are out
of service.

NOTE: When towing has ended, return the machine to

its original condition. Use cables of sufficient strength
for towing.

C7 - C9 - C11 - C15 604.13.235 - 09/2002

26 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3

HYDRAULIC DIAGRAM
Designation
Model: C7 - C9 - C11 - C15
1 Travel pump: 9B Relief valve (left): 200 bar
C7 - C9: 55 cm3 9C Relief valve (right): 200 bar
10 ASC valve
C11 - C15: 75 cm3
11 Hydraulic steering cylinder
1A Pilot circuit relief valve:
12 Divider block
C7 - C9: 24 bar
12A Relief valve (right reverse travel): 450 bar
C11 - C15: 224 bar
12B Relief valve (left reverse travel): 450 bar
1B Relief valve (forward):
13 Pressure switch: 60 bar
C7 - C9: 350 bar
14 Suction strainer
C11 - C15: 420 bar
15 Filtration block
1C Relief valve (reverse):
16 Filling filter
C7 - C9: 350 bar
17 Oil level gauge
C11- C15: 420 bar
18 Combined cooler
2 Vibration pump:
19 Non-return valve: 5 bar
C7 - C9: 46 cm3 20 Thermoregulator: 40°C to 55°C
C11: 42 cm3 22 Quick-coupler
C15: 55 cm3 23 Quick-coupler
2A Pilot relief valve: 24 Quick-coupler
C7 - C9 - C15: 28 bar 25 Temperature sensor
C11: 42 bar 26 Power lift group
2B Relief valve (vibration II): 26A Relief valve: 80 bar
C7 - C9: 345 bar 27 Manual pump
C11 - C15: 400 bar 28 Lifting block
2C Relief valve (vibration I): 29 Hydraulic locking device
C7 - C9: 345 bar 30 Hydraulic motor for lifting the cab
C11 - C15: 400 bar 31 Hydraulic motor for lifting the hood
3 Drum drive hydraulic motor: M1 Reserve travel test point
C7 - C9 - C11: 60 cm3 M2 Forward travel test point
M3 Vibration I test point
C15: 80 cm3
M4 Vibration II test point
4 Vibration hydraulic motor
M5 Steering test point
C7 - C9: 35 cm3 M6 Pressure feed pump test point
C11: 42 cm3 M7 Pilot pressure test point
C15: 55 cm3 HF Hand forward
HR Hand reverse
5 Wheel drive hydraulic motor: 60 cm3
LHR Left-hand reverse
8 Steering pump: 27 bar
LHF Left-hand forward
9 Power steering unit
RHR Right-hand reverse
9A Steering main relief valve:
RHF Right-hand forward
C7 - C9: 140 bar
SR1 Brake pressure switch: 16 bar
C11 - C15: 150 bar

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3 27

Model: C7 - C9
9C 11
9

9B 9A 5 10
15 S21
12 12A
31

30
23
17 bar
247 psi 29
6 bar 4.5 bar
87 psi 65 psi 24

12B

28
22
24
27

13 1C
2C
25 19 16 26
8
14

40°C 55°C
104°F 131°F

17 26A

1 1A 1B 2 2A 2B 4 20 18
CI02B542 4

604.13.235 - 09/2002 C7 - C9 - C11 - C15

28 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3

This page is intentionally left blank

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3 29

Model: C11 - C15

9C 11
9

5 10
9A 9B 15 S21
12 12A 31

30
23

17 bar
247 psi 29
4.5 bar
6 bar
65psi
87 psi 24

12B

28
22
27

13 1C
2C
25 19 16 26
8
14

40°C 55°C
104°F 131°F

17 26A

1 1A 1B 2 2A 2B 4 20 18
CI01E501 4

604.13.235 - 09/2002 C7 - C9 - C11 - C15

30 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3

This page is intentionally left blank

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4 1

SECTION 35 - HYDRAULIC SYSTEM

Chapter 4 - Hydraulic pump

CONTENTS
Section 82021 Description Page
Specifications ................................................................................................. 1
Torque specifications .................................................................................... 1
Description ..................................................................................................... 2
Disassembly ................................................................................................... 3
Reconditioning and replacement of parts ................................................... 8
Assembly ...................................................................................................... 14
Inspection and adjustments ........................................................................ 26

SPECIFICATIONS

Pump 90R042PV Pump 90R055PV Pump 90R075PV

C11 (vibration) C7 (travel) C11 (travel)
Machine (location) C9 (travel) C15 (travel)
C15 (vibration)
Displacement (maximum) 42 cm3 55 cm3 75 cm

Minimum speed 500 rpm 500 rpm 500 rpm

Theoretical torque at max. disp. 0.67 Nm/bar 0.88 Nm/bar 1.19 Nm/bar
Weight 37 kg 40 kg 49 kg

! WARNING ! 1
Be sure to fill the pump housing with clean hydraulic
fluid prior to start up. Fill the housing by pouring fil-
tered oil into the upper case drain port (1).

CS01D530 1

TORQUE SPECIFICATIONS
90R042PV 90R055PV 90R075PV
Swashplate ........................................................................ 13.5 Nm........................13.5 Nm ........................13.5 Nm
Servo-cylinder......................................................................... 9 Nm........................13.5 Nm ...........................24 Nm
Leveler guide ........................................................................ 23 Nm...........................23 Nm ...........................23 Nm
Side cover.......................................................................... 13.5 Nm........................32.5 Nm ........................32.5 Nm
Swashplate guide .............................................................. 13.5 Nm...........................32 Nm ...........................32 Nm
Side cover screws installed in “Blind” holes ...................... 13.5 Nm........................32.5 Nm ........................32.5 Nm
Side cover screws installed in “Thru” holes....................... 10.5 Nm...........................25 Nm ...........................25 Nm

C7 - C9 - C11 - C15 604.13.235 - 09/2002

2 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

DESCRIPTION

25 26 23 22 49
21

24
15 48
17 47 38
37 39

33 34 30 31
31
17 40
18
36
17 35 35
32 34
33
14 28
16
46
13 41

12 27 29 45

19 44 42
20 11
9
8 43
5 6
2 3 10 50 51 52
7
1
4
CS01D586 2
1. Cover 22. Piston 43. Plug
2. Bolt 23. Slipper guide 44. Spring
3. O-ring 24. Guide 45. O-ring
4. Bolt 25. Bolt 46. Pin
5. Adapter 26. Spacer 47. Gasket
6. O-ring 27. Swashplate 48. Adapter plate
7. Plate 28. Leveler, complete 49. Solenoid
8. Spacer 29. Bearing 50. Orifice plate
9. Spacer 30. Piston 51. Spring
10. O-ring 31. Plug 52. Spring retainer cup
11. Coupling 32. Housing
12. Plug 33. Bolt
13. Relief valve 34. O-ring
14. Relief valve 35. O-ring
15. Adjusting screw 36. Shaft
16. Screw 37. Bearing
17. Plug 38. Plate
18. Screw 39. Shaft packing
19. Gasket 40. O-ring
20. End cover 41. Swashplate leveler
21. Cylinder block 42. Cover

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4 3

DISASSEMBLY
90R055PV PUMP
1. Thoroughly clean all external surfaces prior to
removal of the control components.
2. Using a 4 mm internal hex wrench, remove the four
electro-valve mounting screws. Remove the elec-
tro-valve (with O-rings and orifice) from the adapter
plate.
3. Using a 5 mm internal hex wrench, remove the
eight adapter plate mounting screws. Remove the
adapter plate and gasket from the housing.

! WARNING !
Protect exposed surfaces and cavities from damage
and foreign material.

4. Inspect the orifice installed between the valve and CD01D134 3

adapter plate. This orifice must be installed in the
case drain passage for proper pressure limiter
operation.
90R042PV OR 90R075PV PUMPS
5. Thoroughly clean the external surfaces of the con-
trol components.
6. Using a 4 mm internal hex wrench, remove the four
screws and remove the pressure-control-pilot.
7. Check all surfaces for nicks or damage. Clean the
internal screens.

CD01D135 4
8. Thoroughly clean all external surfaces prior to
removal of the control components.
9. Using a 5 mm internal hex wrench, remove the
eight control mounting screws. Remove the control
assembly (with orifice check valve and spring) and
control gasket from housing.

! WARNING !
Protect exposed surfaces and cavities from damage
and foreign material.

CD01D136 5

C7 - C9 - C11 - C15 604.13.235 - 09/2002

4 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

10. Remove the multi-function valve cartridge with a

32 mm hex wrench on the largest hex on the car-
tridge.

CD01D137 6
11. Remove the shim adjustable pressure relief valve
plug with a 25 mm hex wrench.
12. Position the pump with the shaft facing up.

CD01D138 7
13. Remove the three or four screws holding the
retainer plate and seal carrier to the housing using
a 10 mm hex wrench 5 mm internal hex wrench.

NOTE: Certain early production units use a single

piece retainer plate and seal carrier.

CD01D129 8
14. After removing the screws, the spring force on the
shaft may move the seal carrier out of its bore by
approximately 5 mm. If the seal carrier does not
move from its bore after removing the screws, pry it
from its bore as shown and/or lightly tap the end of
the shaft with a soft mallet.
15. Remove the O-ring from the seal carrier.
16. Place the seal carrier and seal in an arbor press
and press out old seal.

CD01D130 9

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4 5

17. After removal of these components, place the

pump on a work surface with the shaft up.
18. Remove the shaft and bearing assembly from the
housing. The bearing outside diameter is a slip fit in
the housing bore.

NOTE: If the shaft and bearing stick in the housing,

lightly tap the end of the shaft with a soft mallet to free
the bearing.
19. Remove the retaining ring and press the shaft out
of the bearing.

NOTE: If the pump is equipped with an auxiliary mount- CD01D054 10

ing pad, temporarily reinstall two of the large screws
which fasten the end cover to the housing. These
screws will hold the end cover against internal spring
pressure while the small screws are removed.
20. Using a 5 mm or 6 mm internal hex wrench or a 10
mm hex wrench, remove the two or three small
screws which fasten the end cover to the pump
housing.
21. Using an 8 mm internal hex wrench for 90R042PV
pumps, a 19 mm hex wrench for 90R055PV
pumps or a 24 mm hex wrench for 90R075PV
pumps, remove the large screws which fasten the
end cap to pump housing.
22. Remove the end cover from the housing. The
alignment pins and valve plate will normally remain
with the housing. Remove the end cover gasket.
Remove the swashplate leveler spring shims (if CD01D055 11
installed) from the spring housings in the end
cover.
23. Remove the three springs from the pump: the two
long swashplate leveler (“T-Bar”) springs and the
short swashplate hold down spring.

NOTE: Certain units are equipped with dual swash-

plate leveler springs (an inner spring “nested” inside
each of the standard springs).
24. Remove the alignment pins and distribution plate,
noting the direction of the arrows on the distribution
plate.

CD01D057 12

C7 - C9 - C11 - C15 604.13.235 - 09/2002

6 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

25. Straighten the locking tabs (used on early produc-

tion units) and remove the six side cover screws
(with flat washers on later production units) using a
10 mm hex wrench for 90R042PV pumps or a
13 mm hex wrench for 90R055PV and 90R075PV
pumps.
26. Remove the side cover and the swashplate leveler
(“T-Bar”) assembly from housing.

CD01D058 13
27. Remove spring seats from swashplate leveler.
NOTE: Early production pumps do not have removable
(hardened) spring seats.
28. For units with leveler guide posts, remove the two
guide posts and sealing nuts holding the leveler to
the side cover. Use a 17 mm open end wrench or a
10 mm hex wrench on 90R042PV frame size
pumps. Use a 3/4 in open end wrench and a 13
mm hex wrench on 90R055PV and 90R075PV
frame size pumps. Remove the swash plate leveler
from the side cover. Remove the side cover O-ring.

CD01D060 14
29. Mark the servo-cylinders and housing to realign
each servo-cylinder with its respective side of the
housing.

CD01D061 15
30. Remove the three or four screws retaining each
servo-cylinder to the housing, using a 10 mm or
13 mm hex wrench.
31. For early production units, carefully pry each cylin-
der from the housing by using a screwdriver in the
notches in the cylinder. For later production units,
install a 8 mm or 10 mm screw in the threaded hole
in the center of each cylinder, and pull the cylinders
from the housing. The servo-piston will remain in
the housing.
NOTE: For later production units with displacement lim-
iters, remove the limiter screw from each servo-cylinder
and install a 8 mm or 10 mm screw in its place to act as CD01D063 16
a puller screw.

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4 7

32. Remove the cylinder block through the housing

end cover opening. The swashplate and piston
assembly will remain in the housing.

CD01D064 17
33. Remove the swashplate bearing cage link pin from
the housing through the control opening.

NOTE: A flat head screw is used as the link pin in

90R042PV frame size pumps. If may be removed with a
3 mm internal hex wrench.
34. Remove the bearing cage locator link from the
swashplate through the control opening.
35. Remove the swashplate and pistons through the
housing side cover opening. Disengage the servo-
arm from the slider block located in the servo-pis-
ton as the assembly is removed.
CD01D065 18
36. Remove the servo-piston and slider block from
housing.

NOTE: Units equipped with an automotive control have

a threaded hole in one end of the servo-piston for the
centering assistance spring assembly. For these units,
note the orientation of the servo-piston in the housing.

CD01D066 19
37. Remove the swashplate cradle bearing cage.
Remove the bearing races. The bearing races are
a loose fit on two locating pins in the housing.

CD01D067 20

C7 - C9 - C11 - C15 604.13.235 - 09/2002

8 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

38. Remove the feedback link from the head of the

special screw on the swashplate assembly.

CD01D068 21
39. Using a 10 mm or 13 mm hex wrench, remove the
four screws holding the slipper guide hold down
mechanism to the swashplate.
40. Remove the piston assemblies from the slipper
guide.

CD01D069 22

RECONDITIONING AND REPLACEMENT OF PARTS

1. After disassembly all parts should be thoroughly
cleaned in a suitable solvent. Replace all O-rings,
gaskets and the shaft seal.
2. Inspect all parts for damage, nicks, or unusual
wear patterns. Replace all parts having unusual or
excessive wear or discoloration.
3. If the end cover journal bearing needs replacement
(as shown by large amounts of the metal backing
of the bearing being visible through the plastic
bearing material), remove the bearing with a suita-
ble puller. Do not damage the valve plate surface of
the end cover.

CD01D070 23

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4 9

4. Lightly lubricate the steel backing of a new journal

bearing. Press the journal bearing into the end
cover using a suitable driver.

CD01D071 24
5. When installed correctly, the bearing will be flush to
0.5 mm (0.019 in) below the distribution plate sur-
face of the end cover.

NOTE: For 90R042PV frame size pumps, the bearing

is located 21 to 21.5 mm from the front surface of the
supply pump recess in the end cover.

CD01D072 25
6. If a new journal bearing is installed, the bearing
must be sized with the appropriate arbor to assure
the minimum bore diameter is met. Carefully press
the sizing arbor into the bearing to size it.

! WARNING !
The arbors are precision finished to size the journal
bearings without damaging them. Damaged arbors
must be replaced. Do not attempt to use the drive
shaft in place of an arbor. Inadequate clearance
between the shaft and bearing will result in inade-
quate lubrication and shortened bearing life.
CD01D073 26
NOTE: The charge pump shaft bushing in the end
cover may be replaced in a similar manner to the drive
shaft journal bearing.

C7 - C9 - C11 - C15 604.13.235 - 09/2002

10 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

7. Certain frame size pumps with twin port end covers

may have the servo-relief valves and rotation plugs
located in a removable rotation block. Remove the
rotation block screws with a 5 mm internal hex
wrench and remove the block and gasket.
For pumps with a pressure limiter function, remove
the servo-relief valves from the end covers or rota-
tion block with a screw driver.
For pumps with the pressure limiter eliminated,
remove the servo-relief passage plug(s) from the
end cover or rotation block with a 3/16 in. (4.8 mm)
internal hex wrench.
90R042PV pump twin port end cover
CS01D533 27
Note the position of the rotation pipe plugs and
remove them from the end cover or rotation block
with a 1/8 in. internal hex wrench.
8. Install the servo-relief valves or relief valve pas-
sage plugs into the end cap or rotation block as
shown in the accompanying illustrations and chart.

NOTE: Pumps with a pressure limiter function MUST

have servo-relief valves installed in the end cover or
rotation block to limit servo-pressures.

90R055PV pump side port end cover

CS01D534 28
9. Install the rotation pipe plugs into the end cover or
rotation block as shown in the accompanying illus-
trations and chart.

90R055PV pump twin port end cover

CS01D535 29

90R075PV pump side port end cover

CS01D536 30

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4 11

90R075PV pump twin port end cover rotation

CS01D537 31
Pressure limiter Servo-relief valves
Pump Pipe plugs in (0-ring plugs for O-ring plugs
Open holes
Port “A” Port “B” rotation holes automotive in holes
control in hole)
YES YES R (CW) 1, 3 6, 7 None 2, 4, 5
YES YES L (CCW) 2, 4 6, 7 None 1, 3, 5
NO NO EITHER 1, 2, 5 None 6 3, 4, 7

! WARNING !
Uncontrollable movement of the vehicle/machine
and its attachments can result from installing the
pressure limiter logic plugs in the incorrect ports for
the pump rotation. Correct pressure limiter function
MUST be verified. This can be accomplished by
testing the pump before it is installed, or by defining
and performing a test in the vehicle/machine before
it is released from repair.

Torque the servo-relief valves or relief valve passage

plugs to 12 Nm. Torque the rotation pipe plugs to 5.4
Nm.
When reinstalling the rotation block and gasket, torque
the screws to 16 Nm.
10. The threaded holes in the swashplate (for the hold
down screws) must be cleaned of old locking com-
pound prior to reassembly. A 6 mm thread tap may
be used for this purpose.
11. Inspect the swashplate guide for wear. The guide
may be removed by removing the special locking
screw with a 5 mm (042 pump) or 6 mm (055 and
075 pump) internal hex wrench.
12. Servo-arm alignment is critical to proper pump
operation. For this reason, removal of the servo-
arm from the swashplate is not recommended.

CD01D074 32

C7 - C9 - C11 - C15 604.13.235 - 09/2002

12 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

13. If the servo-arm must be removed from the swash-

plate, remove the locking screw with a 13 mm hex
wrench.
14. “Keystone” design servo-arms must be parallel
(within 0.25 mm total) to the wide surface of the
slot in the swashplate when installed. “Press fit”
design servo-arms must be carefully aligned with
the slot and threaded holes in the swashplate while
installing, and must be pressed completely into the
swashplate slot.

NOTE: “Keystone” design servo-arms and swashplates

are no longer available for servicing 90R055PV and
90R075PV frame size pumps. A swashplate/servo-arm
kit is available to service these units. Refer to the appro-
priate Service Parts Manual for more information.
15. Torque the servo-arm to swashplate locking screw
to 32 Nm.
16. Assemble the swashplate guide to the swashplate
with the special locking screw. Torque the screw to
13.5 Nm for 90R042PV pump and 32 Nm for
90R055PV and 90R075PV pumps.

CD01D075 33
17. If the headed roll pin and flat washer for the bearing
cage locator link must be installed on the swash-
plate, the distance between the washer and the
side of the swashplate must be as indicated below:

CD01D076 34

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4 13

Distance “H”
Pump frame size
±0.25 mm
90R042PV 3.60
Swashplate Headed pin
90R055PV 5.33
90R075PV 9.45

Flat washer

“H”

CS01D538 35

18. Inspect the servo-piston and seal rings for wear. If

worn, remove the seal rings and expander O-rings
from the piston.
19. Install new expander O-rings into the seal grooves
in the servo-piston.
20. Carefully install the piston seal rings in the piston
grooves, over the expander O-rings. Do not stretch
the seal rings any more than necessary when
installing.
21. Lubricate the seal rings and carefully slide the
servo-piston into the servo-cylinders. Allow the
assembly to settle for at least 5 minutes to allow the
seal rings to return to their original “unstretched”
size. The remove the servo-cylinders.

CD01D077 36
22. Compress the cylinder block spring and remove
the spiral retaining ring, retainer, spring, and spring
seat. Reassemble in the reverse order.

CS01D539 37

C7 - C9 - C11 - C15 604.13.235 - 09/2002

14 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

ASSEMBLY
1. Clean and lightly oil all parts prior to assembly of the
pump. Be sure to torque all threaded parts to the
recommended torque specifications.

! WARNING !
Most parts have critical, high tolerance surfaces.
Caution must be exercised to prevent damage to
these surfaces during assembly. Protect exposed
surfaces, openings, and ports from damage and for-
eign material.

2. Assemble the piston assemblies into the slipper

guide.
3. Lubricate the slipper running surfaces. Center the
pistons and guide on the swashplate.

NOTE: Later production pumps use a fixed-clearance

hold down mechanism. Early production 90R055PV
and 90R075PV frame size pumps use a spring-loaded
hold down mechanism. Service parts for the spring-
loaded hold down mechanism are no longer available. If
hold down parts require replacement on these earlier
production units, the fixed-clearance hold down mecha-
nism must be installed. Refer to the appropriate Service
Parts Manual for more information.
4. Assemble one-half of the fixed-clearance hold
down mechanism as follows: CD01D078 38

- Position two spacers over the threaded holes in the

swashplate as shown.
- Position the slipper guide bearing on top of the
spacers and the slipper guide.

! WARNING !
The “split” between the slipper guide bearing plates
must be located in line with the swashplate arm.
The bearing surface of the bearing plates must be
located next to the guide.

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4 15

5. Install two new screws (with locking compound)

and flat washers through the slipper guide bearing,
and spacers. Finger tighten the screws into the
swashplate.

NOTE: Inspect the flat washers for raised edges or

“burrs”. The smooth side of the flat washers must be
installed next to the slipper guide bearing.

! WARNING !
Always use new screws with proper locking com-
pound.
CD01D079 39
6. Assemble the other half of the fixed-clearance hold
down mechanism in a similar manner.
7. Assemble one-half of the spring-loaded hold down
mechanism as follow:
8. Lubricate the slipper guide bearing and position it
on top of the slipper guide.

! WARNING !
The “Split” between the slipper guide bearing plates
must be located in line with the swashplate arm.
The bearing surface of the bearing plates must be
located next to the slipper guide.

9. Position two spacers in the holes of the guide bear-

ing and over the threaded holes in the swashplate CD01D080 40
as shown.
10. Position two flat washers on top of the spacers.
11. Position two leaf springs on top of the washers.
12. Position two spring aligners on top of the leaf
springs.
13. Install two new screws (with locking compound)
through the spring aligners, leaf springs, flat wash-
ers, and spacers. Finger tighten the screws into
the swashplate.

! WARNING !
Always use new screws with proper locking com-
pound.

C7 - C9 - C11 - C15 604.13.235 - 09/2002

16 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

14. Assemble the other half of the spring-loaded hold

down mechanism in a similar manner. Torque the
hold down screws to 13.5 Nm. The slipper guide
and piston slippers must be able to slide freely on
the swashplate.

CD01D081 41
15. Lubricate the pistons and cylinder block bores.
Install the assembled swashplate and pistons into
the cylinder block by inserting the pistons into the
cylinder block bores. The pistons and bores are not
selectively matched, therefore no specific piston
and bore matching is required.

CD01D082 42
16. Check that the swashplate bearing race locating
pins are secure in the housing.
17. Install the swashplate bearing races into the hous-
ing, positioning the races on the locating pins.
Retain the races in position with petroleum jelly.
The locating pins are offset in the housing to
assure proper assembly.

CD01D067 43
18. Assemble and lubricate the bearing cage, and
install it on the bearing races.
19. Install the bronze slider block on the swashplate
servo-arm.

CD01D163 44

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4 17

20. Install the feedback link on the head of the special

screw on the swashplate assembly.

! WARNING !
To avoid the possibility of the pump sticking in
stroke, the feedback link must NOT be installed in
pumps equipped with non-feedback controls (cover
plate, three position solenoid, and automotive con-
trol type pumps).

CD01D083 45
21. Position the servo-piston in the housing.
22. Carefully lower the cylinder block and swashplate
assembly into the housing through the end cap
opening.

NOTE: A tool to assist in holding and installing the

assembled cylinder block and swashplate may be made
from a positive lock, quick release pin and a large flat
washer (1 inch inside diameter with clearance flats
ground on the outside diameter). Insert the pin through
the cylinder block and swashplate, and lock in place
with the flat washer under the swashplate.

CD01D084 46
23. Hold the cylinder block and swashplate assembly
approximately 12 mm above the cradle bearings.
24. Properly position the feedback link in the control
opening.

CD01D085 47
25. Position the servo-piston on the slider block, taking
care not to wedge the block. The parts should slide
freely.

CD01D086 48

C7 - C9 - C11 - C15 604.13.235 - 09/2002

18 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

26. Lower the cylinder block and swashplate assembly

until the swashplate is properly located on the cra-
dle bearings.

NOTE: If an assembly tool was used to install the cylin-

der block and swashplate, release and remove the pin.
The flat washer should fall through the shaft opening of
the housing.

CD01D087 49
27. Hold the servo-piston in position and install the
servo-cylinders.

NOTE: Be sure to assemble the correct servo-cylinder

on each side of the housing. For units equipped with an
automotive control, a special servo-cylinder is installed
on the centering assist spring side of the housing.
28. Install the three or four screws in each servo-cylin-
der. Torque to 13.5 Nm for 90R042PV and
90R055PV pumps or 24 Nm for 90R075PV
pumps.
29. Align the slot in the swashplate bearing cage with
the headed spring pin in the swashplate and the CD01D088 50
pin hole in the housing. Hook the cage locator link
over the spring pin, between the washer and the
swashplate. Rotate the link into the slot in the bear-
ing cage.
30. Align the hole in the locator link with the hole in the
housing and install the link anchor pin through the
link and into the housing.

CD01D089 51

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4 19

For 90R042PV pump

A flat head screw is used as the link pin in 90R042PV
frame size pumps. Install a new screw (with locking Cage locator
compound) through the locator link and into the hous- Pump housing Link
ing. Tighten the screw into the housing until the head of
the screw is positioned at a height (distance “H”) of 4.53
to 4.79 mm, from the machined surface of the pump
housing. Screw

! WARNING ! “H”
Always use a new screw with proper locking com-
pound. Do NOT torque this screw against the loca-
tor link. The link MUST rotate freely.
CS01D540 52
31. Push the swashplate assembly toward the control
side of the housing until the swashplate guide con-
tacts the bearing race. Check for clearance
between the servo-arm and the slider block. If no
clearance is present, recheck the assembly of the
bearing cage and races.

CD01D090 53
32. Position the swashplate leveler (“T-bar”) on the side
cover. Note the orientation of the leveler and the
cover.

CD01D060 54

C7 - C9 - C11 - C15 604.13.235 - 09/2002

20 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

33. For units with leveler guide posts, install the two
guide posts and sealing nuts. Torque to 9 Nm for
90R042PV pumps or 23 Nm for 90R055PV and
90R075PV pumps.

NOTE: If the screw holes in the side cover are

“through” holes, the threads of the screws must be
coated with sealing compound.

CD01D091 55
34. Install the leveler spring seats.

NOTE: Early production pumps do not have removable

(hardened) swashplate leveler spring seats.

CD01D092 56
35. Install the inner spring spacer washers (if used).
Install a new side cover O-ring.
36. Hold the swashplate leveler toward the end cover
end of the housing so the leveler clears the side of
the swashplate during side cover installation. Install
the side cover and swashplate leveler.

CD01D093 57

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4 21

37. Install two side cover screws (with flat washers) fin-
ger tight into the blind holes in the housing, to hold
the cover while checking the “zero angle” position
of the swashplate.
38. If all the parts which affect the zero angle setting
are being reused, rotate the side cover to align the
marks on the cover and housing that were made
during disassembly.
39. Apply a force of 22 to 44 Nm to the swashplate lev-
eler to ensure both arms are in contact with the
swashplate. Make sure the swashplate is properly
located on its bearings. Use a depth micrometer to
measure the distance from the end cover face of
the housing to the outer edge of the swashplate
surface. Take a second measurement at a point
180° from the first point of measurement (at the
opposite edge of swashplate surface). These
measurements must not vary by more than
0.025 mm.

CD01D094 58
40. Rotate the side cover (which will also rotate the lev-
eler and swashplate) until the zero angle position is
established, as determined by the depth measure-
ment.
41. After the zero angle position has been established,
tighten the two screws to hold the side cover.

CD01D095 59

C7 - C9 - C11 - C15 604.13.235 - 09/2002

22 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

42. Install the remaining four screws with flat washers.

NOTE: The threads of the two side cover screws

installed in “through” holes in the housing must be
coated with a sealing compound to prevent leaks. New
screws have sealant pre-applied.
43. First, torque the four side cover screws installed in
“blind” holes to 13.5 Nm for 90R042PV pumps or
32.5 Nm for 90R055PV and 90R075PV pumps.
Then, torque the two side cover screws installed in
“through” holes to 10.4 Nm for 90R042PV pumps
or 25 Nm for 90R055PV and 90R075PV pumps.

CD01D096 60
44. Install the end cover alignment pins into the hous-
ing. Lubricate the running surface of the cylinder
block and install the distribution plate on the align-
ment pins.

NOTE: Note the direction of the arrow cut-outs in the

valve plate. The arrows must point in the direction of
pump rotation. For example, a right hand (clockwise)
rotation pump must have the arrows pointing in the
clockwise direction (when viewed from the shaft end).
(The photo on this page shows a valve plate installed
for clockwise (CW) rotation).
45. Install the two long springs (with inner springs, if
used) on the swashplate leveler spring seats. CD01D057 61
Install the short spring on the servo-arm link. Place
new end cap gasket on the housing (located by the
alignment pins). Take care not to bend or damage
the end cap gasket during installation.
46. Lubricate the end cover journal bearing. Install the
hardened shims in the end cover pockets for the
swashplate leveler springs. Retain the shims with
petroleum jelly.
47. Lower the end cover onto the housing, while posi-
tioning the three springs in their pockets in the end
cover.
When properly installed, the end cover will engage
on the alignment pins, but the springs will hold the
end cover 3 to 8 mm away from the housing.

CD01D098 62

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4 23

48. Install the four large end cover screws.

NOTE: If the pump is equipped with an auxiliary mount-

ing pad, temporarily install two of the large screws
which fasten the end cover to the housing. These
screws will hold the end cover against internal spring
pressure while the small screws are installed.
Tighten the large end cover screws evenly to the
torque indicated in the accompanying table.

Frame size Torque Nm

90R042PV 75
90R055PV 122 CD01D099 63
90R075PV 256
49. Install the two or three smaller screws holding the
end cover to the housing. Torque the 6 mm screws
to 13.5 Nm and the 8 mm screws to 38 Nm.

NOTE: A lifting bracket is installed on one of the smaller

end cover screws.
50. Position the pump on its end cover.
Using caution to prevent damage to the sealing
surface, press the roller bearing onto the drive
shaft. (For units with a three piece bearing, press
the inner race onto the shaft, then install the outer
race/cage assembly and the special washer).
Install the bearing retaining ring on the shaft.
51. Install the screws and torque to 16 Nm.
52. Install the shaft and bearing assembly through
front of the housing, aligning the shaft spline with
the cylinder block spline. Continue to lower the
shaft into the unit and carefully align the end of the
shaft with the end cover journal bearing. Then
lower the shaft and bearing assembly into position.
53. Rotate the shaft by hand. The rotating assembly
should turn freely. If it does not rotate freely, the
pump must be disassembled and the problem
found and corrected.

C7 - C9 - C11 - C15 604.13.235 - 09/2002

24 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

54. Rotate the pump shaft with a torque wrench to

assure correct assembly. When properly assem-
bled, the torque required to turn the shaft (after
“break-away”) should be within the ranges shown
in the accompanying table.

Rolling torque (variable pump at 0°)

Nm
Frame size Minimum Maximum
90R042PV 37 10.2
90R055PV 5.4 12.2
90R075PV 6.71 13.6

! WARNING !
Always test the pump prior to putting it into service
to check for correct pressure limiting and control
functioning. Improper functioning of these systems
can result in uncontrollable movement of the vehi-
cle/attachments.

90R055PV pump
55. In preparation for installing the adapter plate, place
a new gasket on the housing. Place the adapter
plate into position and install the screws. Torque
the screws to 16 Nm.

NOTE: A sealing washer must be installed under the

head of any mounting screws that are installed into
“thru” holes in the housing.
56. Install new O-rings and the orifice onto the electro-
valve assembly and install the electro-valve onto
the adapter plate. Install the screws and torque to
5.4 Nm.
90R042PV and 90R075PV pump
57. In preparation for installing the control assembly,
place a new gasket on the housing. Inspect to
ensure that the control orifice check valve and
spring are in their proper position in the control
assembly.

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4 25

58. While setting the control assembly into position,

engage the pin on the control linkage into the mat-
ing hole in the link attached to the swashplate.
59. With the control assembly in position, move control
assembly left and right to check engagement of pin
in the link. Proper engagement will be indicated by
an increasing resistance as the control assembly is
moved away from center position. Non-engage-
ment of pin will be indicated by lack of spring force.
In case of non-engagement, remove control
assembly and repeat the above procedure.
60. Align the control assembly gasket and install the
screws. Torque the screws to 16 Nm. CD01D136 64

NOTE: A sealing washer must be installed under the

head of any mounting screws that are installed into
“through” holes in the housing.
61. Install new O-rings in the pilot-control-pressure
housing. Place the pilot-control-pressure against
the electric displacement control housing and
install the screws. Torque to 5.4 Nm.

NOTE: Do not remove the black plastic cover from the

aluminium plate. This is not a serviceable item and will
void the product warranty.

CD01D139 65

90R042PV, 90R055PV and 90R075PV pumps

62. Install the cartridge in the multi-function valve cav-
ity and torque to 89 Nm. Do not over torque the
multi-function valve cartridge.
63. Install the shim adjustable pressure relief valve,
torque to 68 Nm.

C7 - C9 - C11 - C15 604.13.235 - 09/2002

26 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

INSPECTION AND ADJUSTMENTS

INSPECTION OF THE SUPPLY PRESSURE

SAFETY VALVE
Mark the position of the valve in relation to the cylinder
body. Loosen the 27 mm lock nut and remove the safety
valve. Check the valve cone and seat. On reassembling
observe the correct position of the valve in relation to
the mark. Tighten the lock nut to a torque of 46-55 Nm.

CD01D147 66
ADJUSTMENT OF THE SUPPLY PRESSURE
SAFETY VALVE
Loosen 27 mm lock nut and turn the adjustment plug.
By turning clockwise the pressure increases, counter-
clockwise decreases. Thereafter tighten the lock nut to
a torque of 46-55 Nm.

CD01D148 67
ADJUSTMENT OF SAFETY PRESSURE
Turn the screw by the internal hexagonal socket while
holding the middle hexagonal head. Turning clockwise
the pressure increases, counter-clockwise decreases.
One turn changes pressure by 9.3 MPa. Once in the set
position, hold the adjustment screw using key and
tighten the lock nut to a torque of 16 Nm. Follow the
same procedure for the second multi-functional valve.

CD01D149 68

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4 27

ADJUSTMENT OF THE BY-PASS VALVES

The by-pass valve is part of the multi-function valve.
Opening and closing of the valves is carried out with the
motors shut down. For the middle screw of the multi-
function valve use a 27 mm wrench and for the large
screw use a 1-1/4” wrench. Turn the middle screw three
turns counter-clockwise to open the by-pass valve. Do
not turn by more than 3.5 turns; a considerable amount
of oil would leak out.

CD01D150 69

C7 - C9 - C11 - C15 604.13.235 - 09/2002

28 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 4

NOTES

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 39 - FRAMES - CHAPTER 1 1

SECTION 39 - FRAMES

Chapter 1 - Drum
CONTENTS
Section 92013 Description Page
Description ..................................................................................................... 2
Specifications ................................................................................................. 5
Torque specifications .................................................................................... 5
Special tools ................................................................................................... 6
Drum removal ................................................................................................. 9
Vibrator plate assembly .............................................................................. 17
Removal of the right side of the drum ....................................................... 19
Inspection and adjustment of vibration frequency ................................... 24

C7 - C9 - C11 - C15 604.13.235 - 09/2002

2 SECTION 39 - FRAMES - CHAPTER 1

DESCRIPTION
The vibrating drum, together with the driving lugs is fixed to both sides of the front frame using rubberized metal
pieces of the prescribed rigidity. The vibration effect is generated by means of two cams located on both sides of the
drum. The cams are joined by a shaft and actuated by a hydraulic motor that is located on the left side of the drum.
The drum is driven by a hydraulic motor located on the right side of the drum.
Model C7 - C9 / C11 - C15

24
45
21

46
14
17 12
8
10 18 57
40 40 18
3
38
10
23
30
9 38
57 39
7 22 44
33 6
31 15
28 21 44 16
28 37
13
26
17 42
4
11a

2
15
16
41 20 11

CS01D552 1
1. Console 11a.Guide pin 22. Ring 39. Screw
2. Console 12. Cover 23. Collar 40. Screw
3. Vibrator plate 13. Ring 24. Hydraulic motor 41. Brush
4. Vibrator plate 14. Screw 26. O-ring 42. Screw
6. Nuts 15. Spacers 28. Bearing 44. Screw
7. Left cover 16. Spacers 30. Nut 45. Screw
8. Right cover 17. Support 31. Washer 46. Screw
9. Hub 18. Retaining plate 33. Drain plug 57. O-ring
10. Cover 20. Screw 37. Screw
11. Hydraulic motor 21. Rubber mounting 38. Screw

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 39 - FRAMES - CHAPTER 1 3

Model C7 - C9

46

51
49 50
53
52

58

52

59

53
60 51
46

49
54
50 56

54

CS02B558 2
46. Bearing
49. Cam
50. Cam
51. Ring
52. Key
53. Bushing
54. Snap ring
56. Connecting shaft
58. Shaft
59. Key
60. Connecting shaft

C7 - C9 - C11 - C15 604.13.235 - 09/2002

4 SECTION 39 - FRAMES - CHAPTER 1

Model C11 - C15

46

47

49
50

54 53
51
52
46
46
55
54
48

5
53
51
46
55 52

49 54
50

56

CS01D541 3
5. Connecting shaft
46. Bearing
47. Right shaft
48. Left shaft
49. Cam
50. Cam
51. Ring
52. Key
53. Bushing
54. Snap ring
55. Pin
56. Connecting shaft

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 39 - FRAMES - CHAPTER 1 5

SPECIFICATIONS

C7 C9 C11 C15
Drum diameter 1300 mm 1300 mm 1500 mm 1500 mm
Drum width 1680 mm 1680 mm 2200 mm 2200 mm
Drum thickness 25 mm 25 mm 25 mm 40 mm
Fluid capacity of vibrating rollers 6.7 l 6.7 l 8l 8l

TORQUE SPECIFICATIONS

Screws, Tightening torque Nm

Fastening hardware
nuts C7 - C9 C11 - C15
Rubberized metal pieces (21) left, right side 44, 45, 52 XX 75

Covers (12) 46 XX 75
Inside covers (10) 40 XX 165
Vibration hydraulic motor 14 XX 120
Drum (1) to frame (50) mounting 37 XX 315
Left cover (7), right cover (8) 38 XX 315
Hub (9) left cover (7) 39 XX 165
Driving lug (3) hydraulic motor (24) - right side 20 XX 314
Bracket (1), hydraulic motor (24) - right side 19 XX 165

Bearings (28) - 70 - 80 75 - 80

C7 - C9 - C11 - C15 604.13.235 - 09/2002

6 SECTION 39 - FRAMES - CHAPTER 1

SPECIAL TOOLS
No 1. Wrench 39-1-15 (For vibration hydromotor
assembly)

ND090605 4
No 2. Bolts 39-1-01 (For clamping drum rubberized
metal pieces)

ND080073 5
No 3. Clamp 39-1-14 (For securing drums)

ND090535 6
No 4. Handling jig 39-1-06 (For removing consoles
from drum. C7 - C9 - C11 - C15

ND080149 7
No 5. Special wrench 39-1-09 (For removing mount-
ing nut)

ND080229 8

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 39 - FRAMES - CHAPTER 1 7

No 6. Remover 39-1-17 (Disassembly of hub, vibrator

plate and bearing)
1: One version for C7 - C9 - C11- C15 1
2: Bolt M14 for rollers C7 to C15

ND101781 9
No 7. Ring installer 39-1-16 (For oil ring installation)

ND101776 10
No 8. Special wrench 39-1-08 (For establishing coni-
cal bearing pre-load in hub)

ND101777 11
No 9. Handling shaft 39-1-05 (For lids and vibrator)

ND080148 12
No 10. Clamp 39-1-13 (For vertical installation of the
drum) C7 - C9

ND090512 13
No 11. Extractor 39-1-12 (For removing vibrator shaft)
C7 - C9

ND081983 14

C7 - C9 - C11 - C15 604.13.235 - 09/2002

8 SECTION 39 - FRAMES - CHAPTER 1

No 12. Cam installer 39-1-07 (For cam installation)

ND080213 15
No 13. Driver 39-1-02 (For installing bushing in cam)

ND080145 16
No 14. Sleeve 39-1-03 (For setting up positionning pin)
C15

ND080146 17
No 15. Axial play feeler gauge 39-1-04 (For checking
bearing end play)

ND080147 18
No 16. Frequency tester 39-1-18 (For vibration fre-
quency check)

CD01D161 19

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 39 - FRAMES - CHAPTER 1 9

DRUM REMOVAL
1. Raise the drum frame until the drum is just touch-
ing the ground. Support firmly on both sides.

CD01C040 20
2. Remove the cover from the vibration hydraulic
motor.

CD01C041 21
3. Remove the vibration hydraulic motor hose
clamps.

CD01C042 22

C7 - C9 - C11 - C15 604.13.235 - 09/2002

10 SECTION 39 - FRAMES - CHAPTER 1

4. Remove the four screws from the vibration hydrau-

lic motor. Remove lower bolts using fixtures No. 1.

CD01C043 23
5. Slide out the hydraulic motor and set it to one side
of the frame.

CD01C044 24
6. Remove the hose clamps on the rear cross mem-
ber of the frame.

CD01C045 25
7. Remove the travel hydraulic motor hose clamps.

CD01C046 26

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 39 - FRAMES - CHAPTER 1 11

8. Place a suitable receptacle underneath the travel

hydraulic motor.
9. Remove the travel hydraulic motor hoses.
10. Plug the hoses and the hydraulic motor ports.

CD01C047 27
11. Attach the hoses to the mirror.

CD01C048 28
12. Disconnect the wires from the travel hydraulic
motor (sensor, solenoid).

CD01C049 29
13. Unscrew the plugs in the front cross member and
install the hooks.
14. Use a suitable lifting device to suspend the cross
member.

CD01C050 30

C7 - C9 - C11 - C15 604.13.235 - 09/2002

12 SECTION 39 - FRAMES - CHAPTER 1

15. Remove the screws on both sides and set the

cross member to one side.

CD01C051 31
16. Loosen the frame/bracket connecting screws (37)
on the left side, and (9) on the right side.

37 9

CD01C052 32

17. Insert the tool No. 2 clamping bolts.

No. 2

CD01C053 33
18. Tighten the rubberized metal pieces an extra
8-10 mm.

8-10 mm No. 2

CD01C054 34

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 39 - FRAMES - CHAPTER 1 13

19. Following removal of the screws remove the spac-

ers (15, 16).

15
16

CD01C055 35
20. Roll the drum from the frame. Position the drain
plug (33) in the left cover in the lower position.

33

CD01C056 36
21. Use chock No. 3 to prevent any machine move-
ment.
22. Unscrew the drain plug (33) from the vibrator cover
and drain the oil into a receptacle.

NOTE: Make sure that the last two screws to be

removed are the ones that allow alignment of the con-
sole in vertical position. No. 3

CD01C057 37
23. By turning the console (2), remove the screws (39)
stepwise. The two screws placed horizontally are
to be removed first after the tool has been
attached.

39 2

CD01C058 38

C7 - C9 - C11 - C15 604.13.235 - 09/2002

14 SECTION 39 - FRAMES - CHAPTER 1

24. Position the console (2) vertically and using tool

No. 4 attach it to a suitable lifting device.
No. 4
25. Remove the remaining two screws (39).

39 39

CD01C059 39
26. Remove the console together with the vibrator
No. 2 No. 2
plate from the drum and set it to one side. Remove
the tool No. 2 screws one after the other.

CD01C060 40
27. Remove the screws (44) and remove the console
(2) from the rubberized metal pieces.

44

CD01C061 41
28. The vibrator plate is to be rotated and placed on
the rubberized metal pieces.
29. Remove the safety washer (31).
NOTE: Remember to wear eye protection.

31

CD01C062 42

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 39 - FRAMES - CHAPTER 1 15

30. Place tool No. 7 on the nut (30).

No. 7

CD01C063 43
31. Remove the nut (30) and washer (31).
30

31

CD01C064 44
32. Rotate the vibrator plate and support.
33. Remove the screws (42).

42

CD01C065 45
34. Insert the screws in the holes (tool No. 8), and by
tightening evenly remove hub (9). If necessary use
screw tool No. 8.
No. 8

CD01C066 46

C7 - C9 - C11 - C15 604.13.235 - 09/2002

16 SECTION 39 - FRAMES - CHAPTER 1

35. Press out the bearing (28) from the hub, the seal
ring (22) and the collar (23).
23

22
28

CD01C067 47

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 39 - FRAMES - CHAPTER 1 17

VIBRATOR PLATE ASSEMBLY

For assembly, follow removal procedure in reverse
order.
28
1. Press the outer race of the bearing (28) into posi-
tion and install the seal ring (22) using tool No. 9.
22
28

CD01C067 48
2. Install the O-ring (26) and ring (13) on the vibrator
plate bearing, pre-heated to 90°C (when replac-
ing). Insert the inner part of the bearing (28); pre-
heat to between 90 and 110°C.
28

26
13

CD01C068 49
3. Fill the bearings with grease and insert the hub (9).
4. Insert the inner part of bearing (28); pre-heat to 28
between 90 and 110°C.

9
CD01C069 50

C7 - C9 - C11 - C15 604.13.235 - 09/2002

18 SECTION 39 - FRAMES - CHAPTER 1

5. Insert the pad (31), nut (30) and tighten with tool
No. 7 (tap slightly on the tool while tightening).
No. 10
6. Tighten the nut using tool No. 10.

CD01C070 51

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 39 - FRAMES - CHAPTER 1 19

REMOVAL OF THE RIGHT SIDE OF THE DRUM

1. Turn the drum to the position shown.
2. Use tool No. 4 to suspend console (1) with a suita-
ble lifting device.
3. Remove the screws (45) from console (1). 45
12
4. Set the console with the driving lug to one side. No. 4

CD01C071 52

! WARNING !
In roller C7 - C9 the vibration exciter in the twin ver-
sion (left and right vibrator) of two vibrators on the
same shaft. For the reason of higher weight, the
vibration exciter is removed (installed) in the vertical
position of the drum from the left side. When replac-
ing the bearing of the right lid, it is necessary to place
the drum with its left side down by means of two
clamps No. 12 on suitable padding (beams of hard-
wood).

NOTE: Steps 8 to 12 must be performed only on the

C11 to C15.
5. To remove the cover (12), remove the screws (38),
suspending the cover on tool No. 11 and using
three screws in service holes "A" to press the cover
from the front of the drum.
A
6. Set the cover to one side. A

No. 11

38
CD01C072 53

C7 - C9 - C11 - C15 604.13.235 - 09/2002

20 SECTION 39 - FRAMES - CHAPTER 1

7. Using the same tool, remove the vibrator.

No. 11

CD01C073 54
8. Remove the screws (40), retaining plate (18) and
cover (10) and press out the outside races of the
bearings (46) from covers and remove the con-
necting shaft (5). 10
40
9. Follow the same procedure for removing the cov-
ers and vibrator on the left side of the drum.
18 5 46

CD01C074 55

NOTE: Step 13 must be performed only on the C7 -

C9.
10. Before removing the vibrator, position the drum
vertically with its right side down. Having removed
the left lid, pull the vibrator out of the drum using
tool No. 13.

CD02B051 56

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 39 - FRAMES - CHAPTER 1 21

11. Warm up the bearing races (46) to between 90 and

110°C (194 and 230°F) and slide then off the
shafts. 46 46

C11 - C15 C7 - C9

CD02B050 57
12. Take out the ring half-segments (51) and the loose
cam (50). The rigid cam may be removed by mill-
ing the cam body (49) in its weakest point, or by 47 48
using a new shaft (47), (48) complete with cam 49
(49).

51

50

CD01C076 58
13. When assembling the cam using new parts, shaft
(47), (48) along with key (52) must be pressed first 47 48
into a preheated cam (49) (250-350°C). The cam
must be placed on tool No. 14.
52
49

No. 14

CD01C077 59
14. Press the bushing (53) into the cam (50) using tool
No. 17.
15. Calibrate the bushing using tool No. 17.

53 50
No .17

CD01C078 60

C7 - C9 - C11 - C15 604.13.235 - 09/2002

22 SECTION 39 - FRAMES - CHAPTER 1

16. When installing the outer bearing races (46) in the

covers (7), (8), match with the internal bearing 46
races.
NOTE: Further operations are identical for both sides of
the drum and for assembly the procedure may be fol-
lowed in reverse.
NOTE: For C7 - C9: First install the right lid with the 8
bearing, position the drum vertically using clamps 7
No. 13, and install the vibrator using tool No. 13. When
the vibration exciter is in place, check axial free play of
bearings of the exciter.

CD01C079 61

NOTE: Steps 20 and 21 must be performed only on the

C11 to C15.
17. Install the snap ring (54). For installation of the con-
necting shaft (5), the vibrators must be synchro-
nized; this is done by aligning groove "A" on both
ends of the shaft with the pins (55) in cam (47) and A
(48).

54 5

CD01C080 62
18. Press the pins (55) into both shafts (47) and (48),
positioning with tool No. 18.

55

47
48

CD01C081 63

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 39 - FRAMES - CHAPTER 1 23

19. After installing the covers (7 and 8), check the

assembly using tool No. 19. Axial play of the bear-
ings of both vibrators should be 1.5-2.5 mm.

No. 19

CD01C082 64
20. For replacement of the vibration hydraulic motors
(11), guide pin (11A) must be heated up to 200°C,
11
and slid on the output shaft of the hydraulic motor.
The guide pin on the spline must bottom freely and
must not be forced. 11A
21. Coat the hydraulic motor (20) screws with
Loctite 577.

20

CD01C083 65

C7 - C9 - C11 - C15 604.13.235 - 09/2002

24 SECTION 39 - FRAMES - CHAPTER 1

INSPECTION AND ADJUSTMENT OF VIBRATION FREQUENCY

1. Measure maximum speed of engine by means of
the stroboscope. Adjust with regulating bolt (A) of
the injection pump. The machine should be without
load.
A
Speed value (rpm)
C7 - C9 2200 + 30

C11 - C15 2250 + 30

CD02B057 66
2. Adjust the speedometer according to speed of the
engine after dismantling of the dashboard.

CD02B058 67
3. Place the sensor of the instrument against the
plate and measure the frequency.
4. If the frequency differs from that specified in this
manual, adjust it by means of the adjusting screws
on the vibration pump.

CD01D161 68

Machine C7 C9 C11 C15

High amplitude Hz (rpm) 30 (1800) 30 (1800) 32 (1920) 29 (1740)
Low amplitude Hz (rpm) 40 (2400) 40 (2400) 35 (2100) 35 (2100)

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 39 - FRAMES - CHAPTER 1 25

5. C7 - C9
The frequency of high amplitude vibration is
adjusted by the lower screw (A only). Loosen
safety screw (B) and using a wrench, turn the set-
up screw (A), adjust to required value and tighten
safety screw. Frequency increases with the screw
being turned counter-clockwise, and vice versa.

B
A
CD01G324 69
C11 to C15
Loosen the lock nut (2) and use a screw driver to A
turn the adjusting screws (1) (unscrewing gives
higher frequency, tightening gives lower fre-
quency).
The upper screw "A" adjusts frequency for high
amplitude. The lower screw "B" adjusts frequency
for low amplitude.
Do not adjust to a higher frequency than that spec-
ified by the manufacturer. Do not switch the fre-
quencies, the lower frequency must work in 2
conjunction with the higher amplitude and vice B
versa. Both low and high frequencies are factory 1
adjusted. CD01D162 70

C7 - C9 - C11 - C15 604.13.235 - 09/2002

26 SECTION 39 - FRAMES - CHAPTER 1

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 39 - FRAMES - CHAPTER 2 1

SECTION 39 - FRAMES

Chapter 2 - Articulation
CONTENTS
Section 92020 Description Page
Specifications ................................................................................................. 1
Torque specifications .................................................................................... 1
Description ..................................................................................................... 2
Special tools ................................................................................................... 3
Disassembly ................................................................................................... 5

SPECIFICATIONS
Max. vertical frame swing ...............................................................................................................................± 10°
Max. horizontal steering angle ........................................................................................................................± 36°

TORQUE SPECIFICATIONS

Screw Torque Nm
Screws
item No. C7 - C9 C11 - C15
Drum frame, plate (2) 40 XX 549 (405)

Rear frame, plate (1) 39 XX 314 (231.6)

Plate (2), bearing (23) 38 XX 165 (121.7)

Bearing (23), hub (3) 37 XX 118 (87)

Hose clamp (6), plate (1) 36 XX 75 (55.3)
Cover (11), hub (3) 34 XX 75 (55.3)
Steering cylinder pin packing (17) 35 XX 75 (55.3)

C7 - C9 - C11 - C15 604.13.235 - 09/2002

2 SECTION 39 - FRAMES - CHAPTER 2

DESCRIPTION
The articulation connecting the drum frame to the rear frame is equipped with a large-size bearing with cross rollers
allowing for the frame to swing vertically, and two vertical pins allowing side movement for steering.
C7 - C9 / C11 - C15 models

36
39
17
12 10
34

11
25
24
3 34
13

1 17

11 35
9
37

5 21

40 10
18
9
34

2 4

38
CS01C505 1
1. Bearing 21. Ring
2. Frame plate 24. Bearing
3. Hub 25. Nut
4. Pin 34. Screw
5. Shim 35. Screw
9. Ring 36. Screw
10. Cover 37. Screw
11. Cover 38. Screw
12. Pin 39. Screw
13. Spacer 40. Screw
17. Pad
18. Pad

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 39 - FRAMES - CHAPTER 2 3

SPECIAL TOOLS
No 1.Bearing removal tool 39-2-05 (for removing bear-
ing)

ND101782 2
No 2.Wrench 39-1-15 (for vibration hydromotor assem-
bly)

ND090605 3
No 3.Double-hook chain 39-2-01 (for removing drum)

ND090586 4
Handling chain four hook 39-2-02 (for removing
drum)

ND090588 5
No 4.Suspension hook 39-2-04 (for handling bearing)

ND103875 6

C7 - C9 - C11 - C15 604.13.235 - 09/2002

4 SECTION 39 - FRAMES - CHAPTER 2

No 5.Handling shaft 39-1-05 (for lids and vibrator)

ND080148 7
No 6.Wrench 39-2-03 (for removing nut)

ND090610 8

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 39 - FRAMES - CHAPTER 2 5

DISASSEMBLY
1. Place the machine on flat firm ground and support
the frame in front.

CD01C084 9
2. Support the frame at the rear.

CD01C085 10
3. Remove the shims (5).
4. Using special tool No. 1, remove the pins (4) from
the ends of the hydraulic cylinder rods, along with 4
the rings (9) and seal rings (21).
NOTE: Remember to wear eye protection.

9
21

No. 1

CD01C086 11

C7 - C9 - C11 - C15 604.13.235 - 09/2002

6 SECTION 39 - FRAMES - CHAPTER 2

5. Remove the hose clamps on the drum frame.

CD01C045 12
6. Remove the hose clamps on the articulation and
the rear frame.

CD01C088 13
7. Remove the vibration hydraulic motor cover.

CD01C041 14
8. Remove the vibration hydraulic motor screws. Use
tool No. 2 for the bolts.
9. Slide the hydraulic motor from the drum and place
it to one side.

No. 2

CD01C043 15

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 39 - FRAMES - CHAPTER 2 7

10. Attach the drum to a lifting device using special tool

No. 3.
11. Remove the bolts (40) and the pad (18).
12. Place the drum to one side with the front frame to
the right of the machine.

18 40

CD01C089 16
13. Attach a lifting device to the frame (2). Remove the
screws (38). Place the plate (2) to one side.
2
38

CD01C090 17
14. Loosen the screws (37).

37

CD01C091 18
15. Place special tool No. 5 under the upper screw and
attach a lifting device using special tool No. 6.
Place the bearing to one side.

No. 5

No. 6

CD01C092 19

C7 - C9 - C11 - C15 604.13.235 - 09/2002

8 SECTION 39 - FRAMES - CHAPTER 2

16. Loosen and remove the nut (25) using wrench

No. 7.

No. 7

CD01C093 20
17. Remove the pads (17) and press the pins (12) out
of the bearings using a hydraulic press.

CD01C094 21
18. Use a lifting device to place the hub assembly (3)
on one side.

CD01C095 22
19. Remove the covers (10, 11) and the spacers (13).
20. Press out the bearings (24).
11
24

10
13

CD01C096 23

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 39 - FRAMES - CHAPTER 2 9

NOTES

C7 - C9 - C11 - C15 604.13.235 - 09/2002

10 SECTION 39 - FRAMES - CHAPTER 2

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 39 - FRAMES - CHAPTER 3 1

SECTION 39 - FRAMES

Chapter 3 - Drum Segments and Scrapers

CONTENTS
Section 92013 Description Page
Specifications ................................................................................................. 1
Hardware torque ............................................................................................ 1
Special tools ................................................................................................... 1
Description ..................................................................................................... 2
Segment installation ...................................................................................... 3

SPECIFICATIONS

HARDWARE TORQUE
Screws and nuts for segments....................................................................................................................314 Nm

SPECIAL TOOLS
No 1.Clamps

CS01D542 1

C7 - C9 - C11 - C15 604.13.235 - 09/2002

2 SECTION 39 - FRAMES - CHAPTER 3

DESCRIPTION

5
9

12
16

21

7
6

11
11

CS01D547 1
5. Plugs
6. Rear scraper
7. Front scraper
9. Screws
11. Screws
12. Screws
16. Nut
21. Washer

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 39 - FRAMES - CHAPTER 3 3

SEGMENT INSTALLATION ON SMOOTHDRUM UNIT

1. Place the machine on firm and flat ground.
2. Use a suitable lifting device to suspend the front
scraper with clamps for smooth drums.

CD01C141 2
3. Remove the scraper screws (9).

CD01C142 3
4. Lower the scraper to ground and set it to one side.

CD01C143 4

C7 - C9 - C11 - C15 604.13.235 - 09/2002

4 SECTION 39 - FRAMES - CHAPTER 3

5. Follow the same procedure for removal of the rear

scraper.

CD01C144 5
6. Remove the plugs in the drum frame.
7. Clean the surface of the drum thoroughly.

CD01C145 6
8. Lift the first segment using the holes provided.

CD01C146 7
9. Place it on the drum.

CD01C147 8

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 39 - FRAMES - CHAPTER 3 5

10. Fasten with the four No. 1 clamps (two on each

side). Before tightening, even up the segment
edges with the edge of the drum.
No.1

CD01C148 9
11. Drive slowly forward for about 1.6 metres, while
checking that the clamps do not interfere with the
drum frame.

CD01C149 10
12. Position the second segment, leaving a gap of
about 26 mm between the segments. Connect the
segments using hardware items (see figure 1,
page 2).

CD01C150 11
13. Move forward again, place the third segment in
position and proceed as before with the second
segment.
Tighten the screws, move the machine so that the
segments settle down on the drum, check the
screws and then tighten fully to a torque of 314
Nm.

CD02B100 12

C7 - C9 - C11 - C15 604.13.235 - 09/2002

6 SECTION 39 - FRAMES - CHAPTER 3

14. The second nut is a thread protection only. It must

6 mm (0.24 in)
protrude beyond the end of each segment bolt.
Protrusion 6 mm.

CS02C515 13
15. Install the segment scrapers (6, 7) supplied with
the segments on the front member and the rear
cross-member of the drum frame. Adjust the gap
between scraper and the drum to 30 mm. Previ-
ously removed screws (11) and pads may be used
if required. Tighten to a torque of 314 Nm.

11
7
6

CD01C152 14

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 41 - STEERING - CHAPTER 1 1

SECTION 41 - STEERING

Chapter 1 - Control
CONTENTS
Section 50110 Description Page
Specifications ................................................................................................. 1
Special tools ................................................................................................... 1
Description ..................................................................................................... 2
Troubleshooting - Steering ........................................................................... 3
Disassembly and assembly of steering wheel ............................................ 3

SPECIFICATIONS

SPECIAL TOOLS
No. 1Special washer 41-1-01 (For assembly / disas-
sembly of steering wheel)

ND080755

C7 - C9 - C11 - C15 604.13.235 - 09/2002

2 SECTION 41 - STEERING - CHAPTER 1

DESCRIPTION

5 6 8

4 6

2 3
9
1

7
CS01C508 2
1 Steering pump
2 Steering control valve
3 Main relief valve (C11 - C15: 150 bar; (C7 - C9: 140 bar)
4 Relief valve (left) : 200 bar
5 Relief valve (right) : 200 bar
6 Steering cylinders
7 Hydraulic reservoir
8 Filtration block
9 Pressure switch : 60bar

STEERING WITHOUT ACTIVATION ACTIVATION OF STEERING TO THE RIGHT

Oil is pumped from the tank by the steering pump and Oil is pumped by the steering pump from the oil tank
oil under pressure passes through the open center of and passes under pressure through the open port of
the power steering into the filtration block. the power steering, over the steering hydraulic motor
into the steering cylinders.
Devices for supplying closed circuits are connected to
the output of the filtration block. By the effect of the movement of the steering cylinders,
oil passes from opposite openings to the filtration block
through the power steering, and to supply the closed
circuits.

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 41 - STEERING - CHAPTER 1 3

TROUBLESHOOTING - STEERING

PROBLEM POSSIBLE CAUSES CORRECTION

Steering is defective, the wheel Steering control valve Inspect and repair
gets stuck
Steering does not work in difficult Low pressure Adjust pressure
terrain Worn pump Replace pump
Steering goes to one side Defective servo-reverse valve Inspect and repair

DISASSEMBLY AND ASSEMBLY OF STEERING WHEEL

Remove the steering wheel cup (6) and the nut (21)
and insert tool No. 1 under the steering wheel. Remove
the steering wheel using a steering wheel spanner, dis- 7 6
mantle the steering wheel bracket (1) and slide it with
the steering rod (2) out from the steering column. 21
Remove the snap rings (30), (31) and press shaft (2)
out together with the bearing. Remove the bearing (9) 25
from the shaft.
9
Press the bearing on the shaft (the bearing must be 31
degreased and fresh grease must be applied), secure it 30
18
with the snap ring (31), press it into bracket (1), secure
with the snap ring (30) and mount it to the steering col-
umn. Check that no clearance can be detected 1 26
between bracket (1) and the steering column after the
shaft has been set in steering. Mount the steering 2
wheel.

CS01C507 3

C7 - C9 - C11 - C15 604.13.235 - 09/2002

4 SECTION 41 - STEERING - CHAPTER 1

NOTES

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 41 - STEERING - CHAPTER 2 1

SECTION 41 - STEERING

Chapter 2 - Steering cylinders

CONTENTS
Section 50761 Description Page
Specifications ................................................................................................. 1
Special torques .............................................................................................. 1
Special tools ................................................................................................... 2
Removal of steering cylinders ...................................................................... 3
Replacing the seals ....................................................................................... 4

SPECIFICATIONS

SPECIAL TORQUES

C7 - C9 C11 - C15
Piston rod/piston/nut assembly 130 Nm 140 Nm
Cylinder body/cover assembly 180 Nm 200 Nm

C7 - C9 - C11 - C15 604.13.235 - 09/2002

2 SECTION 41 - STEERING - CHAPTER 2

SPECIAL TOOLS
No. 1 Spanner 35-1-02 (for gland disassembly) C7 -
C9

ND101784 1
Spanner 35-1-05 (for gland disassembly)

ND101785 2
No. 2 Hydraulic cylinder piston installer 35-1-01 (for
assembling piston in hydraulic cylinder)

ND101783 3
No. 3 Bearing removal tool 39-2-05 (for removing
bearing)

ND101782 4

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 41 - STEERING - CHAPTER 2 3

REMOVAL OF STEERING CYLINDERS

16

11
10

11

10

16

CS01C510 5
Place the machine on firm flat ground. Turn the steering wheel as far as it will go and lift the cab for easier access.
Place a tray under the hydraulic cylinder. Disconnect the hoses and plug them up. Remove the shims (11) and screws
(16), and extract the pins (10) from the ends using special tool No. 3. Push the piston rod in after the piston rod pin
has been pressed out. Remove the hydraulic cylinder from the machine using a suitable lifting device, sliding it out
through the rear frame opening towards the drum.

C7 - C9 - C11 - C15 604.13.235 - 09/2002

4 SECTION 41 - STEERING - CHAPTER 2

REPLACING THE SEALS

Place a tray under the hydraulic cylinder and plug the
ports. Drill the safety pin out out off front cover face (10)
(or remove the locking device employed, depending on
the type of the hydraulic cylinder. Remove the cover 8 5 4 10
(10) using wrench No. 1 (depending on the type of the
hydraulic cylinder), slide the piston rod (4) with the pis-
ton (5) out and remove the nut (8) and the piston.
Remove the cover (10).

CS01C509 6
Dip all new seals in oil before installation.
Grease all sliding surfaces and inspect for damage to all 1 6 2 3
sliding surfaces. Install parts with new seals only after
straightening out the seals. At least 15 minutes should
elapse between the installation of new seals and the
completion of the hydraulic cylinder assembly. Use spe-
cial tool No. 2 for the installation of the piston rod with
the piston in the cylinder body. Tighten threaded
assemblies to the torque specified.

5 4

CS01C509 7

ASSEMBLY SEALING MATERIAL KITS

ITEM NO. DESCRIPTION QTY

1 T19 Packing 1
2 T20 Collar 1
3 Wiper ring 1
4 Guide band 2
5 Ring 1
6 Ring 2

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 41 - STEERING - CHAPTER 3 1

SECTION 41 - STEERING

Chapter 3 - Steering control valve

CONTENTS
Section 50743 Description Page
Specifications ................................................................................................. 1
Tightening torques ......................................................................................... 1
Description ..................................................................................................... 2
Special tools ................................................................................................... 3
Disassembly ................................................................................................... 4
Checking the steering elements ................................................................... 7
Reassembly .................................................................................................... 7

SPECIFICATIONS
Technical data and set values for assembly
Setting for valve piston in housing (hydraulic center) ........................................................................ 2.3±0.01 mm
Setting tolerance for hydraulic center ................................................................................................... ± 0.05 mm
Disks (42) - distance gauge - valve piston ................................................................... Thicknesses 1.5 to 2.1 mm
Steering spindle - slip torque .................................................................................................................max. 8 Nm

TIGHTENING TORQUES
Hexagon bolts (1)- cover (2) .....................................................................................................................32±3 Nm
(for servostats with nominal pressure up to 150 bar)
40±3 Nm
(for servostats with nominal pressure up to 180 bar)
Pressure relief valve (19) ........................................................................................................................30 ± 3 Nm
Bolts securing the steering system in its bracket .......................................................20 ± 3 Nm - 4 bolts M8, 10.9
Filter insert (29).......................................................................................................................................12 ± 3 Nm
Hexagon nut - steering wheel ..............................................................................................................35 to 45 Nm

C7 - C9 - C11 - C15 604.13.235 - 09/2002

2 SECTION 41 - STEERING - CHAPTER 3

DESCRIPTION

5
7
5
6 49
5
3
4 44
2
11 42 47
21 39
20 29 10 41
1 38
19 12
45 43 5
13 48
46
16 18 23
17 27
9 15
34 28
40
37 14 24 25 26
36
26 31
32 23
25 33
35 24 30
23 28
22 23
8 36

CS01E526 1
NOTE: Reference numbers are those used in the disassembly/assembly procedure.
1 Bolts 26 Cover disk
2 Cover 27 Plug
3 Spacer 28 Pressure spring
4 Compensating disk 29 Filter
5 O-ring 30 Valve seal
6 Rotor-set 31 Valve seal
7 Cover disk 32 Ball
8 Drive shaft 33 Tapened plug
9 Housing 34 Stop bush
10 O-ring 35 Spring washer
11 Plug 36 Spacer
12 Pressure spring 37 Spring carrier
13 Pressure relief valve 38 Coupling piece
14 Poppet 39 Steering spindle
15 Seal disk 40 Pin
16 Cover disk 41 Axial needle
17 Pressure spring 42 Compensating disk
18 Valve guide bearing 43 Back-up ring
19 Valve insert/plug 44 O-ring
20 O-ring 45 Name plate
21 Check valve 46 Round head grooved pin
22 Plug 47 O-ring
23 O-ring 48 Seal ring
24 Popper 49 Flange
25 Seal disk

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 41 - STEERING - CHAPTER 3 3

SPECIAL TOOLS
No 1.Separator 41-3-01 (For removing pressure relief
valve on steering control valve)

(a) (b)
CI02B512 2
No 2.Mandrel with aligning bush 41-3-02 (For seal ring
flange on steering control valve)

(a) (b)
CI02B513 3
No 3.Gauge holder 41-3-03 (For measuring the valve
piston and drive shaft on steering control valve)

CI02B514 4
No 4.Gauge insert 13 mm 41-3-04 (For measuring the
valve piston and drive shaft on sterring control
valve)

CI02B515 5

C7 - C9 - C11 - C15 604.13.235 - 09/2002

4 SECTION 41 - STEERING - CHAPTER 3

DISASSEMBLY
In order to ensure reliable functioning of the Steering
valve within the overall steering system, absolute clean-
liness must be ensured during removal, storage of the
parts and assembly.
1. Remove the bolts (1).
2. Remove the following parts in succession: Cover
(2), Compensating disk (4) (if fitted), additional 4
spacer (3), rotor set (6) and cover disk (7). 3
2
5
7
1 5
6
5

CS01E517 6
3. Match mark the joint on the housing (9) to the
flange (49). 43 44
47
4. Remove the flange (49) from the housing (19).
48
5. Remove the spring (12) with the pressure relief 12
valve. 13
6. Remove the short-circuit valve comprising the plas- 5 49
42
tic valve guide (18) with spring (17), poppet (14),
seal disk (15) and cover disk (16). 41
7. Remove the coupling piece (38). 18 38 39
8. Remove the steering spindle (39) with axial needle
14 15 16 17
bearing (41) and compensating disk (42) from the
flange. CS01E518 7

9. Remove the valve piston complete with stop bush

(34), spring carrier (37) and drive shaft (8) from the
housing (9).
11
10. Separate the stop bush (34), spring carrier (37), 10
drive shaft (8) and pins (40). Only remove the plug 34
36
(11) with O-ring (10) if necessary. If wear or dam- 37
age is not visible, the spacer disk (36) and spring 40
washers (35) should not be separated from the
spring carrier (37). 8 9

35 36
CS01E519 8

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 41 - STEERING - CHAPTER 3 5

11. Remove the plug (33) and valve seats (30) from
the housing. Remove the balls (32) and valve seats
(31).

31 23
32
30
23

9 33
CS01E520 9
12. Using a hook, press the plug on the hand-pump
side through the R-connection from the housing
25 26
port. Remove the poppet (24) with seal disk (25)
and cover disk (26). 9 24
13. Press the cylinder replenishing valve, comprising
the poppet (24), seal disk (25), cover disk (26),
pressure spring (28) and plug (27) out of the hous- 23
28
ing on the flange side, using a mandrel. 27
23
22
28 26 25 24
CS01E521 10
14. Unscrew the check (21) from the “P” connection.

21

9
CS01E522 11
15. Unscrew the filter insert (29) from the housing (9).

29

9
CS01E523 12

C7 - C9 - C11 - C15 604.13.235 - 09/2002

6 SECTION 41 - STEERING - CHAPTER 3

16. Remove valve insert (19).

NOTE: The valve insert may only be dismantled for 20

cleaning. In the case of wear or pressure deviations, the
entire valve must be replaced. Since the valve setting 19
cannot be corrected, the valve must be re-assembled
using the same components. Valve insert on some
models volumetric cannot be dismantled.

CS01E524 13
17. Screw the hexagon nut, No. 1 (part “b”) onto the
threaded part of the pressure relief valve. Place the 202
spacer, No. 2 (part “a”) onto the valve shaft and
engage the hexagon nut with the spacer.
a
18. Clamp a hexagon socket screw wrench (c) verti-
cally into the vice (d) and place the valve insert with
the hexagon socket on the wrench. b
19. Using a wrench, width across flats 27, turn the hex- 201 c
agon nut against the spacer, until screw plug (201)
and sleeve (202) separate.
d

! WARNING !
CI02B511 14
The valve is spring pre-tensioned.

20. Remove the valve piston (203), pressure spring

(205), washer (206), spring plate (207) and valve 201 204 208 209 205 206
body (208). Remove the washer (209) and pres-
sure pin (210) from the valve body (208). Remove
the O-ring (204) from the valve piston.

210 207 203 202

CS02B559 15

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 41 - STEERING - CHAPTER 3 7

CHECKING THE STEERING ELEMENTS

All parts must be thoroughly cleaned in a cleaning
agent. Seal rings and other rubber elements must not
be cleaned in trichlorethylene, but using a detergent
which dissolves copletely in water.
All parts must be checked for wear, damage or other
defects in order to decide whether the parts can be
reused.

REASSEMBLY
1. Place a greased O-ring (23) on the plug (22) with
projection on the face. Assemble the poppet (24)
with seal disk (25), cover disk (26) pressure spring 25 26
(28) and plug (22) and place this in the handpump
24
side bore on the housing. The plug should be flush
with the housing surface.
23
2. Place a greased O-ring (23) on the plug (27) with-
out projection on the face. Assemble the poppet 26 27
(24) with seal disk (25), cover disk (26) pressure 23 9
spring (28) and plug (27) and place this in the 22
flange-side bore on the housing. The plug should
be flush with the housing surface.
28 26 25 24
CS01E521 16
3. Press a dummy plug (11) with greased O-ring (10)
into the housing bore flush with the flange.
4. In the vice, compress the spring assembly, com- 11
prising at the two external spacers (36) with the 10
punched hole on the inside, and the two internal 34
36
spring washers (35), with the spring recess in the 37
middle facing one another. Install this assembly in 40
the carrier. Center the spring assembly in the car-
rier. Install the spring carrier (37) and in the stop 8 9
bush (34), the shorter drive cams on the stop bush
should align with the shorter driver grooves on the
spring carrier. 35 36
5. Install the stop bush with spring carrier into the CS01E519 17
valve piston so that it still turns easily; align the spi-
ral spline of the stop bush with the three drive cams
on the valve piston. Turn the stop bush in until the
two drives on the opposite side overlap over the full
length.
6. First place the drive shaft (8) with pin (40) in the
valve piston assembly; the drive shaft pin should
be aligned with a common longitudinal groove in
the stop bush and/or valve piston. The position of
the stop bush alignment to the valve piston
described in paragraph 5, above should be main-
tained.
7. Slide the valve piston assembly into the housing
with the two drive cams on the flange side.

C7 - C9 - C11 - C15 604.13.235 - 09/2002

8 SECTION 41 - STEERING - CHAPTER 3

8. Place the gauge (large model, 1/100 mm scale, at

least 15 mm total stroke) into the eccentric clamp
hole of the gauge holder No. 5. The gauge holder
has a recess with precise tolerance. On an even
surface, such as the cover (2), clamp the gauge in
the holder so that the stroke is roughly halved. Set
the gauge to “zero”.
9. Secure the gauge holder with three bolts on the
flange side of the housing and turn one driver cam
on the stop bush to the tracer pin. Position the
valve piston and drive shaft facing this set-up. Note
the value on the gauge in this position. Record the
measured valve obtained, (e.g 7.15 mm). Remove
the gauge holder from the housing; do not change
the setting.
10. Place the axial needle bearing (41) and compen-
sating disk (42) on the steering spindle (39). Insert 43 44
the steering spindle (39) in the flange (without the 17
built in seal rings). Place the gauge holder on the 18
flange and read off the value facing the polished 12
face of the steering spindle; turn the steering to 9 13
contact the axial bearing. Measured value
obtained, for example, 7.20 mm. Correct the differ- 42 5 49
ence of 0.05 mm by fitting a thicker compensating
41
disk (42), refer to the technical data. Remove the
valve piston assembly and steering spindle from 18 38 39
the housing and flange.
14 15 16 17
PRE-ASSEMBLE FLANGE CS01E518 18

11. Lightly grease the O-ring (44) and place it in the

external radial groove of the flange bore (49).
12. Compress the back-up ring to form a heart and
place it on the O-ring (44). Ensure that the back-up
ring contacts the O-ring all round.
13. Place the flange on the work bench with the orifice
side up wards. Place No. 2 (part “a”) with the coni-
cal opening upwards into the flange. Place the
lightly greased O-ring over the seal ring and place
both parts in the tool. Using No. 2 (part “b”), press
the seal ring into the flange.
14. Place the axial needle bearing (41) and compen-
sating disk (42) on the steering spindle (39) in suc-
cession. Press the steering spindle into the flange,
being careful of the seal elements. The steering
spindle should not be repeatedly pushed in and
taken out once the seal elements have been fitted.
15. Place the coupling piece (38) on the steering spin-
dle (39) with the flat tang of the coupling piece in
the driver groove of the steering spindle. Place the
O-ring (5) into the flange.

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 41 - STEERING - CHAPTER 3 9

16. Assemble the poppet (14) with seal disk (15), cover
disk (16) pressure spring (17) and valve guide (18)
in succession, and place the assembly in the
flange-side housing bore. Place the combined
shutoff and pressure relief valve (13) into the
flange-side housing bore with the locating spring
on the outside, together with the pressure spring
(12).
17. Install the flange (49) on the housing (9). The
short-circuit valve (23) matches the unmachined
cast recess of the flange exactly. Engage the driver
cams of the stop bush with the coupling piece by
turning the steering spindle.
18. Place O-ring (5) on the housing. Place the cover
disk (7) with the visible oil chambers facing the
housing, but otherwise as desired.
4
19. Turn the drive shaft until the two alignment marks 3
are parallel to the vertical housing connection side. 2
20. Place one O-ring (5) in each groove of the external
5
rotor of the rotor set (6). Position the rotor set; the 7
open rotor chamber must point towards the hous- 5
ing connection side. 1
6
21. Place the spacer (3) (if fitted) and the compensat- 5
ing disk (4) on the drive shaft.
22. Place a gauge in the center bore of the No. 3. CS01E517 19
Unscrew the base of the gauge’s tracer pin, replac-
ing it with a base with a plane surface diameter of
13 mm, No. 4. Place the gauge on a plane surface
of the cover (2), and set to “zero”.
23. Unscrew guide bolt (4). Tightly screw the gauge
holder with two cover bolts (1) and washers onto
the rotor set. Turn the steering spindle using No. 8,
and note the position reaching the highest value on
the gauge. Stop turning the steering spindle at this
point, lightly pressing the base of the tracer pin so
that the internal steering elements are moved
down.
24. Note the measured value. Deduct the drive shaft
play from the measured result (refer to the techin-
cal data). The difference can be corrected by
installing a thicker washer (53) (refer to the techni-
cal data for gradations).
25. Remove the gauge holder. Position the cover (2)
and screw in the hexagon bolts (1). Only bolts of
the length and type specified in the spare parts list
may be used. Refer to the technical data for tight-
ening torques.
26. Check the slip torque of the internal steering ele-
ments by turning manually. If this check reveals a
high torque, the cover bolts must be removed and
the housing aligned to the cover by repeatedly
turning the steering spindle. Then retighten the
cover bolts with the recommended torque.

C7 - C9 - C11 - C15 604.13.235 - 09/2002

10 SECTION 41 - STEERING - CHAPTER 3

27. Tightly screw the filter insert (29) into the central
threaded hole on the housing connection side.
Refer to page 1 of this section for tightening tor- 13
ques.

9
CS01E523 20
28. Screw the check valve (21) into the "P"-connection
and tighten using a hexagon socket screw wrench.
21
29. Clean the parts thoroughly using approve cleaning
solutions; rubber and plastic parts must not be
cleaned using trichloroethylene. Blow through
holes.

9
CS01E522 21
30. Place the O-ring (204) in the groove on the valve
piston (203). Being careful of the O-ring, press the 201 204 208 209 205 206
valve piston into the sleeve (202).
31. Place the pressure pin (210) in the valve body
(208). Cover the valve body with the plastic washer
(209). Place the plate spring (207) and pressure
spring (205) onto the valve body.
32. Place washer (206) in the valve piston. This
washer has been selected by the manufacturer. If
no washer was fitted, the valve must be reassem-
bled without a washer.
210 207 203 202
33. Place the pre-assembled part into the valve piston
and then fit the screw plug (201). Clamp the CS02B559 22
assembly and press the sleeve (202) onto the snug
fit of the screw plug (201).
34. Tightly screw in the valve insert with O-ring (20) fit-
ted.

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 41 - STEERING - CHAPTER 3 11

35. Clamp the assembly device into the vice so that the
two lateral housing bores are up. Then place a
valve guide (31), with locating ball on the outside,
and a ball (32) into each hole.
31 23
36. Screw the valve guides with fitted greased O-rings 32
(23) into the housing bores. So that the hose safety 30
valves can later be set on the test bench, screw the
23
valve guides in until the outside O-rings are just
inside the gauge bores.

9 33
CS01E520 23

C7 - C9 - C11 - C15 604.13.235 - 09/2002

12 SECTION 41 - STEERING - CHAPTER 3

NOTES

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 44 - WHEELS - CHAPTER 1 1

SECTION 44 - WHEELS

Chapter 1 - Wheels
CONTENTS
Section 44000 Description Page
Specification ................................................................................................... 1
Torque specification ...................................................................................... 1
Special tool ..................................................................................................... 1
Description ..................................................................................................... 2
Disassembly of wheel .................................................................................... 3
Assembly ........................................................................................................ 3

SPECIFICATION
Tires ............................................................................................................ C7 - C9: 14.9x24; C11 - C15: 23.1x26
Wheel inflation pressure .............................................................................................................................. 1.6 bar

TORQUE SPECIFICATION
Nuts fastening wheel to hub........................................................................................................................540 Nm

SPECIAL TOOL
No 1.Handling 44-101 (for wheel removal) (C7 - C9)
Handling 44-102 (for wheel removal) (C11 - C15)

ND080533 1

C7 - C9 - C11 - C15 604.13.235 - 09/2002

2 SECTION 44 - WHEELS - CHAPTER 1

DESCRIPTION

CS02B599 1

1. Rim 4. Plug
2. Tire 5. Bolt
3. Valve 6. Washer

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 44 - WHEELS - CHAPTER 1 3

DISASSEMBLY OF WHEEL
1. Hoist the rear frame of the machine.
2. Remove bolts (5) and washers (6).

5
6

CD02B104 2
3. Remove the tire using tool No. 1.
No. 1

CD02B105 3

ASSEMBLY
1. Clean the rim and hub mating surfaces.
2. Fit the new wheel using tool No. 1.
3. Tighten the bolts slightly until the wheel is correctly
positioned on the hub.
4. Inflate the tire to a pressure of approximately
1.5 bar.
5. Lower the vehicle and tighten the nuts to the speci-
fied torque:
. Wheel nuts: 540 Nm.
6. Inflate to the specified pressure.

C7 - C9 - C11 - C15 604.13.235 - 09/2002

4 SECTION 44 - WHEELS - CHAPTER 1

NOTES

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 50 - HEATER - AIR-CONDITIONING - CHAPTER 1 1

SECTION 50 - HEATER - AIR-CONDITIONING

Chapter 1 - Removal and installation

CONTENTS
Section 90310 Description Page
Specifications ................................................................................................. 1
Removal .......................................................................................................... 2
Air-conditioning system defects .................................................................. 4
Replacing (tightening) the belt ..................................................................... 5

SPECIFICATIONS
Cooling power ................................................................................................................................................. 3 kW
Voltage .............................................................................................................................................................24 V
Current ...............................................................................................................................................................6 A
Coolant..........................................................................................................................................................R134a
Quantity of coolant ...................................................................................................................................... 0.95 kg
High-pressure protection............................................................................................................................2.7 MPa
Low-pressure protection ............................................................................................................................0.2 MPa

C7 - C9 - C11 - C15 604.13.235 - 09/2002

2 SECTION 50 - HEATER - AIR-CONDITIONING - CHAPTER 1

REMOVAL
1. Loosen the filler cap (33).

33

CD01C131 1
2. Open the drain valve on the radiator.
3. Drain the coolant into a suitable container.

CD01C018 2
4. Raise the cab. (See operator’s manual)

CD01C117 3

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 50 - HEATER - AIR-CONDITIONING - CHAPTER 1 3

5. Remove the heater cover.

CD01C132 4
6. Disconnect the air pipes, wiring, and remove the
heater control valve from the cab frame.

CD01D133 5
7. Disconnect the heater supply and return hoses.

CD01D134 6

C7 - C9 - C11 - C15 604.13.235 - 09/2002

4 SECTION 50 - HEATER - AIR-CONDITIONING - CHAPTER 1

8. Remove the screws that attach the heater return

hose on the cover.

CD01C135 7
9. Remove the heat exchanger.

CD01C136 8

AIR-CONDITIONING SYSTEM DEFECTS

Always call service for repairs

DEFECT CAUSES
The unit Check compressor belt
doesn’t cool Check evaporator fan.
Check fuses F6 in the fuse box
See Operator’s manual
Check coolant level in inspection
orifice of the dryer filter. Leakage
receiver - (bubbles, fogging up,
etc...)
Check solenoid switch, with engine
running with air conditioning on the
switch doesn’t react (no click in
compressor)
1. Defective fuse F6,
2. Defective thermostat
3. Defective pressure protection

604.13.235 - 09/2002 C7 - C9 - C11 - C15

5 SECTION 50 - HEATER - AIR-CONDITIONING - CHAPTER 1

REPLACING (TIGHTENING) THE BELT

Loosen the screws (16, 17) and the belt (13) (remove/
replace) by swinging compressor (12) in the (-) direction.
Tighten using a suitable lever by swinging the compres- 17
sor in the (+) direction.

12
16
13
17
CS01D587 9

C7 - C9 - C11 - C15 604.13.235 - 09/2002

 SECTION 50 - HEATER - AIR-CONDITIONING - CHAPTER 1 6

NOTES

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1 1

SECTION 55 - ELECTRICAL CIRCUIT

Chapter 1 - Wiring diagram

CONTENTS
Section 40000 Description Page
Electrical installation ..................................................................................... 1
Functional description ................................................................................... 2
Electrical legend ............................................................................................ 4

ELECTRICAL INSTALLATION

OVERALL FUNCTION
The electrical installation consists of two 12 volt batteries in series, an alternator and other control and indicating
devices. Operating voltage is 24 V. The negative pole of one battery is connected to the machine frame through a bat-
tery master switch. The battery master switch connects or disconnects the supply to the machine electrical system.
In addition to the conventional automotive type circuits in the machine, a number of electronic components are used,
for example, some circuits are protected by diodes, some instruments use thyristors, etc.
A hydraulic control block is controlled by a computer located below the instrument panel.
IMPORTANT: All welding work on the machine is prohibited, without disconnecting all sensitive components from the
power supply and/or dismantling them, if possible, in advance. For example, data stored inside the computer can be
erased by welding close to it. In the following section, you will find circuit diagrams of the machine electrical system
and interconnections of the individual circuits.

C7 - C9 - C11 - C15 604.13.235 - 09/2002

2 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1

FUNCTIONAL DESCRIPTION

PLACING THE STARTER SWITCH KEY IN SITUATION AFTER SHIFTING THE TRAVEL
POSITION 1 ON LEVER FROM ITS NEUTRAL POSITION
FORWARD (WORKING SPEED)
After placing the starter switch key in position 1, the
engine and the machine are in rest position. The battery - The S13 switch goes OFF, the K4, K5 relays release,
master switch is ON. the H5 neutral position indicator lamp goes OFF.
- a 24 V current runs to the F3 fuse - this current flows - From K5, current flows to INP - the A2 timer. It
through S10, S11 to the UB contact of a brake timer. switches the ground to Y6 (a solenoid switch comes
ON); the machine brakes are released.
- In addition, the H6 indicator lamp is supplied from F3;
thereafter the current passes through the S21 brake - The S21 brake pressure switch disconnects, the H6
pressure switch to the ground. The indicator lamp is brake indicator goes OFF and supply of the travel cir-
ON; the machine is braked. cuits through K5, K6 to S17 and simultaneously of
S16 (fast speed) begins.
- The current continues through the S13 neutral posi-
tion switch, current runs to K5 that goes ON, thereby,
FAST TRAVEL SPEED
connecting contacts 3 and 5 and this supplies the H5
neutral position indicator lamp and the E16, E17 By switching S16 ON, current reaches solenoid valves
brake lamps. Y7, Y14 inside the wheels, and through the A4 Compu-
ter it reaches the Y8 solenoid valve.
- In addition, the current flows to A4; after passing
through the F4 and F5 fuses the other measuring - Supply for the A3 travel lever comes through the S16
instruments and indicator lamps are supplied. “Turtle/Hare” switch (contacts 6-2).
- The H9 engine oil pressure warning lamp is ON. - Because the S16 terminal (contact 8) is deprived of
current, the K7 cannot switch ON and vibration can-
- The engine hourmeter is not functioning, because 0
not operate.
Volts (ground) is coming from the D+ output on the
alternator.
STOPPING THE MACHINE
STARTING THE ENGINE - Shifting the travel lever into middle position results in
switching the S13 switch ON; the K5 relay is acti-
- On starting up.
vated, connecting contacts 3-5. The A2 brake timer
Current is arriving at K1 and activating a coil; it is con- input (INP contact) is deprived of current, and timing
nected to a starter motor, simultaneously activating the begins. 3 seconds later, the circuit in A2 is broken
Y5 solenoid (engine stop). It will be held switched-on (loss of ground on the AUT contact), the Y6 magnet
also after starting completion, being held by current loses its supply and disconnects the pressure circuit
from K3. to the brakes. This results in the machine brakes
being applied.
Solenoid conductors - Switching conductor
- After loss of pressure in the brake circuit, the S21
Holding conductor
pressure switch is ON and the H6, H5 indicator lamps
Ground come ON, along with the E16 and E17.
- On the D+ terminal of the G3 alternator, current
increases to 24 V and begins to supply the P5 hourm-
eter; the H10 battery charge indicator lamp goes OFF.
Pulses are coming from the alternator (W terminal)
through the B line, putting the P4 engine tachometer
into operation.
- After working oil pressure is reached in the engine,
the S26 pressure switch goes OFF and the H9 engine
oil pressure lamp as well.

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1 3

STEERING ACTIVATION WITH THE MACHINE IN

HALTED (BRAKED) POSITION
When the steering wheel of the machine is turned, the
steering circuit is pressurized; this results in switching
the S15 steering pressure switch ON, current flows to
the input INP of the A2 timer and the timer will connect
Y6 to the ground. The machine brakes are released.
- When the steering system is no longer sollicited, the
S15 steering pressure switch goes OFF and the A2
timer is started again. Three seconds later this results
in the brakes being applied once more.
- The S35 push-button serves to cancel the A2 timing
function. It is used when climbing a gradient, for
example, where a danger exists of backward motion
within the timer delay after shifting the travel lever into
position 0.

C7 - C9 - C11 - C15 604.13.235 - 09/2002

4 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1

ELECTRICAL LEGEND
A1 - Turn indicator control (optional)
A2 - Brake timer
A3 - Travel control
E1 - Instrument panel lighting
E2, 3 - Front marker lights (optional)
E4, 5 - Tail lights (optional)
E6, 7 - Front headlights
E8, 9 - Rear headlights
E10, 11 - Left turn indicator lights (optional)
E12, 13 - Right turn indicator lights (optional)
E14 - Cab lighting
E15 - Safety beacon (optional)
F1 - Fuse 20A
F2 - Fuse 20A
F3 - Fuse 7.5A
F7 - Fuse 50A
G1, 2 - Batteries
G3 - Alternator
H1 - Indicator lamp for turn indicators (optional)
H2 - Horn
H3 - Back-up alarm (optional)
H4 - Hydraulic oil level indicator
H5 - Travel control neutral position indicator
H6 - Brake indicator
K1 - Contactor
K2-6 - Auxiliary relay
M1 - Starter
M2 - Electric motor for hood and cab lifting system
Q1 - Battery master switch
S1 - Push button for cab lifting system
S2 - Push button for hood lifting system
S3 - Switch box
S4 - Front headlight switch
S5 - Rear headlight switch
S6 - Hazard light switch (optional)
S7 - Turn indicator change-over switch (optional)
S8 - Rotating beacon switch (optional)
S9 - Horn push button
S10 - Right-hand control arm switch
S11 - Emergency brake push button
S12 - Back-up alarm switch (optional)
S13 - Neutral position switch (on travel control)
S14 - Hydraulic oil reservoir float
S15 - Steering pressure switch
S35 - Parking brake push button
V1, 3 - Blocking diode
X2-32 - Connectors
X27 - Rotating beacon socket
Y1 - Cab lifting electro-valve
Y2 - Cab lowering electro-valve
Y3 - Hood lifting electro-valve
Y4 - Hood lowering electro-valve
Y5 - Engine STOP electro-valve
Y6 - Brake electro-valve

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 CS02B587

C7 - C9 - C11 - C15
CAB LIFTING

CAB LOWERING

HOOD LIFTING

HOOD LOWERING

FRONT MARKER
LIGHTS

TAIL LIGHTS

FRONT
HEADLIGHTS

REAR
HEADLIGHTS

CAB LIGHTING
LEFT FRONT TURN
INDICATOR LIGHT
LEFT REAR TURN
INDICATOR LIGHT

RIGHT REAR TURN

INDICATOR LIGHT
RIGHT FRONT TURN
INDICATOR LIGHT

SAFETY BEACON

HORN
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1

BACK-UP ALARM

HYDRAULIC OIL
TANK FLOAT

ENGINE STOP

BRAKE

STEERING PRESSURE
SWITCH
604.13.235 - 09/2002
5

1
6 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1

A3 - Travel control
A4 - Differential lock control block (optional)
A5 - Longitudinal inclination detector (optional)
B1 - Engine oil temperature detector
B2 - Hydraulic oil temperature detector
B3 - Fuel gauge detector
F4 - Fuse 10A
H7 - Vibration pre-selection indicator
H9 - Engine lubrification indicator
H10 - Battery charge indicator
H11 - Air filter restriction indicator
H12 - Hydraulic filter restriction indicator
K7 - auxiliary relay
P1 - Engine temperature detector
P2 - Hydraulic oil temperature detector
P3 - Fuel gauge
P4 - Speedometer
P5 - Hourmeter
R1 - Resistor 470 Ω
R2 - Resistor 330 Ω
S16 - Fast travel switch
S17 - Speed pre-selector switch
S18 - Vibration change-over switch
S19 - Vibration switch (on travel control)
S20 - Gas lever terminal switch
S21 - Brake pressure switch
S22 - Differential lock switch (optional)
S23 - Drum speed sensor (optional)
S24 - Left wheel speed sensor (optional)
S25 - Right wheel speed sensor (optional)
S26 - Engine lubrification pressure switch
S27 - Air filter restriction
S28 - Hydraulic filter depression switch
X4-28 - Connector
X25 - Diagnostic socket (optional)
Y7 - Fast travel speed (left wheel) electro-valve
Y8 - Fast travel speed (drum) electro-valve
Y9 - Vibration I electro-valve
Y10 - Vibration II electro-valve
Y11 - Differential lock -electro-valve LH wheel (optional)
Y12 - Differential lock -electro-valve RH wheel (optional)
Y13 - Travel servo-valve
Y14 - Fast travel speed (right wheel) electro-valve

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 CS01E502

C7 - C9 - C11 - C15
FAST TRAVEL SPEED-
LEFT WHEEL

FAST TRAVEL SPEED-

RIGHT WHEEL

VIBRATION I

VIBRATION II

BRAKE PRESSURE
SWITCH

FAST TRAVEL SPEED

(DRUM)

DIFFERENTIEL LOCK
LEFT VALVE

RIGHT WHEEL
VALVE

LONGITUDINAL
INCLINATION DETECTOR

DRUM SPEED SENSOR

LEFT WHEEL SPEED

SENSOR

RIGHT WHEEL SPEED

SENSOR
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1

SERVO-VALVE

ENGINE TEMPERATURE

HYDRAULIC OIL
TEMPERATURE

FUEL GAUGE /
SPEEDOMETER

ENGINE LUBRICATION
AIR CLEANER / CHARGING /
HOURMETER

HYDRAULIC OIL FILTER

604.13.235 - 09/2002
7

2
8 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1

F4 - Fuse
F5 - Fuse 15A
F6 - Fuse 20A
K7 - Auxiliary relay
K8 - Auxiliary relay
M3 - Cab ventilation fan
M4 - Front windshield wiper
M5 - Rear windshield wiper
M6 - Front windshield washer
M8 - Heating fan
S16 - Fast travel switch
S18 - Vibration change-over switch
S29 - Cab ventilation selector
S30 - Front windshield wiper
S31 - Rear windshield wiper
S32 - Windshield washer push button
S33 - Heating fan selector
S36 - Drum traction spin limiting switch
V4 - Blocking diode
V5 - Blocking diode
X4-26 - Connectors
Y7 - Fast travel speed (left wheel) electro-valve
Y8 - Fast travel speed (drum) electro-valve

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 CS02B588

C7 - C9 - C11 - C15
CAB VENTILATION VAN

FRONT WINDSHIELD WIPER

REAR WINDSHIELD WIPER

WINDSHIELD WASHER, FRONT

WINDSHIELD WASHER, REAR

HEATING FAN

FAST TRAVEL SPEED -

LEFT WHEEL

FAST TRAVEL SPEED -

RIGHT WHEEL
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1

FAST TRAVEL SPEED

(DRUM)

604.13.235 - 09/2002
9

3
10 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1

NOTES

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 90 - PLATFORM, CAB - CHAPTER 1 1

SECTION 90 - PLATFORM, CAB

Chapter 1 - Operator’s compartment

CONTENTS
Section 90310 Description Page
Torque specifications .................................................................................... 1
Operator’s compartment ............................................................................... 2
Travel brake control adjustment ................................................................... 8

TORQUE SPECIFICATIONS
M8 nut on the wiper arm ........................................................................................................................... 9-10 Nm
M10 nut on the wiper arm .............................................................................................................................25 Nm

C7 - C9 - C11 - C15 604.13.235 - 09/2002

2 SECTION 90 - PLATFORM, CAB - CHAPTER 1

OPERATOR’S COMPARTMENT

OPERATOR’S COMPARTMENT ASSEMBLY

Removal
1. Loosen the operator’s compartment retaining nuts.

CD01C115 1

CD01C116 2
2. Tilt the compartment see operator’s manual.

CD01C117 3

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 90 - PLATFORM, CAB - CHAPTER 1 3

3. Disconnect the cable on the injection pump (3),

drain the coolant partially and disconnect the
heater hoses (1, 2) and electrical cables. Remove 2
the power steering assembly underneath the cab, 1
disconnect the anchor chain and lower the cab.
Connect a suitable lifting device to the eye bolts on
the cab roof and place it to one side.

CD01C118 4

Installation
For installation, follow the removal procedure in reverse
order and add coolant.

CAB
Removal
1. Rear the window wiper removal - remove the cover
(6), wiper, nut on the wiper shaft (1), screws (9)
and clamps with the wiper motor.

CD01C119 5

9 9

CD01C120 6

C7 - C9 - C11 - C15 604.13.235 - 09/2002

4 SECTION 90 - PLATFORM, CAB - CHAPTER 1

2. Front wiper removal - remove the screws (75) from

the upper cover (14).

75
14 75

CD01C121 7
3. Disconnect the cables, remove the drive nut (2)
and the drive (1). Disconnect the cables and
remove the clamp (6) with the fan (14).

14
2
6 2
1

CD01C122 8
4. Remove the wiper nut (1) and drive shaft nut (2).

1
2

CD01C123 9

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 90 - PLATFORM, CAB - CHAPTER 1 5

DOOR LOCKS
1. Remove the lower cover (10).

10

CD01C124 10
2. Remove the nut (63), disconnect the rods (64, 65)
and remove rod (64).

65

63

64
CD01C125 11
3. Remove the flange (103), loosen the screws (75)
and remove the handle with the push-button and
washers.
75

103

64
75

CD01C126 12

C7 - C9 - C11 - C15 604.13.235 - 09/2002

6 SECTION 90 - PLATFORM, CAB - CHAPTER 1

4. Remove the screws (81) and the left and right

locks (8).

81
8

CD01C127 13

Installation
For installation, follow the same procedure in reverse
order. Set up the push-button and the lock by adjusting
nut (63).

SEAT
1. Tilt the control panel (1) on the right side of the
seat, remove the cover (2) below, disconnect the
cables, free and fold.

CD01C128 14
2. Remove the cover bellows, remove the nuts and lift
out the seat. Remove the screws (20) and the grid
(8) on both sides.

8
20
CD01C129 15

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 SECTION 90 - PLATFORM, CAB - CHAPTER 1 7

3. Remove the cover (6) and the seat plate (1).

CD01C130 16
4. Remove the ball (13) from the seat plate, free the
snap ring (26) and pull out the pin (8), and the
1 13
spring (11).
26

11

9 8

10 6

22
24
5 17
CS01C520 17

C7 - C9 - C11 - C15 604.13.235 - 09/2002

8 SECTION 90 - PLATFORM, CAB - CHAPTER 1

TRAVEL BRAKE CONTROL ADJUSTMENT

Remove the screws (1), the instrument panel with the
control and the cabling.
Remove the screws (2) and the control. Unscrew the
control plastic cover and set the brakes on the control
lever.

2
1

CD01D157 18
The control may be fixed in position using an adjustable
clamp. The travel control operates also as a service and
parking brake. The vibrator push button is located in the
lever to be ready to interrupt of vibrations any time.

CD01D154 19

604.13.235 - 09/2002 C7 - C9 - C11 - C15

 Service Manual

Service Manual

Service Manual
✍ ✍ ✍

VIBRATORY VIBRATORY VIBRATORY

ROLLERS ROLLERS ROLLERS
C7 - C9 C7 - C9 C7 - C9
C11 - C15 C11 - C15 C11 - C15

604.13.235 604.13.235 604.13.235

Service Manual

Service Manual

Service Manual

✍ ✍ ✍
VIBRATORY VIBRATORY VIBRATORY
ROLLERS ROLLERS ROLLERS
C7 - C9 C7 - C9 C7 - C9
C11 - C15 C11 - C15 C11 - C15

604.13.235 604.13.235 604.13.235