Case 121B - 221B Wheel Loaders Operator's Manual 9-81930 - PDF DOWNLOAD

Operator’s Manual 121B : DAH1218600 and after 221B : DAH2218600 and after Cre 9-81930 GB

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121B - 221B Wheel Loaders

Template Name: OM_1_col Template Date: 1994_04_29

THIS SYMBOL MEANS "WARNING - SAFETY" AND SHOWS IMPORTANT SAFETY MESSAGES. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH.

WARNING IMPROPER OPERATION OF THIS MACHINE OR THE NONOBSERVANCE OF SAFETY INSTRUCTIONS CAN CAUSE SERIOUS INJURY OR DEATH. TRIM THIS EDGE

BEFORE USING THIS MACHINE : 1. CAREFULLY READ THIS MANUAL. 2. MAKE SURE THAT THIS MACHINE HAS THE RIGHT ATTACHMENTS AND TOOLS FOR THE TYPE OF WORK TO BE CARRIED OUT.

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3. BE AWARE OF CURRENT TRADE AND PRIVATE JOB SITE REGULATIONS. 4. OBSERVE CURRENT ROAD TRAFFIC REGULATIONS DURING TRAVEL ON PUBLIC HIGHWAYS.

Any reproduction or translation, even partial, is forbidden without the written authorization of Case France Cre 9-81930 GB Copyright  1997 Case France Issued December 1997

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IDENTIFICATION NUMBERS/MACHINE COMPONENTS ......................... 10 - 12 TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE.................................................................................... 10 IDENTIFICATION OF THE MAIN COMPONENTS ....................................... 12

CONTROLS/INSTRUMENTS/ACCESSORIES ........................................... 38 - 60 CAB DOORS ................................................................................................. 38 STEPS AND ACCESS HANDLES................................................................. 39 MONITORING PANEL................................................................................... 40 CONTROL PANEL......................................................................................... 42 CONTROL SWITCHES ................................................................................. 44 OPERATOR’S COMPARTMENT CONTROLS ............................................. 45 OPERATOR’S SEAT ..................................................................................... 54 FUSE BOXES ................................................................................................ 55 REAR WINDOW ............................................................................................ 55 HEATING AND VENTILATION...................................................................... 56 REAR VIEW MIRRORS................................................................................. 57 AIR CONDITIONING ..................................................................................... 57 TOWING RING .............................................................................................. 58 FUEL TANK ................................................................................................... 58 ENGINE HOOD ............................................................................................. 59 FRONT PANEL.............................................................................................. 60 WHEEL CHOCK ............................................................................................ 60 MACHINE TOOLS ......................................................................................... 60 OPERATING INSTRUCTIONS .................................................................... 61 - 75 BEFORE OPERATING THE MACHINE ........................................................ 61 OPERATING THE MACHINE ........................................................................ 62 RUNNING-IN PERIOD................................................................................... 64 STARTING THE ENGINE.............................................................................. 65 SHUTTING DOWN THE ENGINE ................................................................. 67 OPERATING THE MACHINE IN COLD WEATHER ..................................... 68 OPERATING THE MACHINE IN HOT WEATHER........................................ 69 TRANSPORTING THE MACHINE................................................................. 70 TOWING ........................................................................................................ 73 1

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SAFETY/DECALS/HAND SIGNALS ........................................................... 13 - 36 SAFETY RULES ............................................................................................ 13 DECALS......................................................................................................... 24 HAND SIGNALS ............................................................................................ 34

Template Name: OM_1_col Template Date: 1994_04_29

TO THE OWNER ............................................................................................. 5 - 9 121B AND 221B SERIES WHEEL LOADERS ................................................ 5 TO THE OWNER ............................................................................................. 6 PRESENTATION ............................................................................................. 8 RIGHT, LEFT, FRONT AND REAR OF THE MACHINE ................................. 9

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TABLE OF CONTENTS

Operating instructions (continued) OPERATING THE MACHINE IN WATER ..................................................... 75 PARKING THE MACHINE............................................................................. 75

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JOB SITE AND ROAD OPERATION .......................................................... 76 - 80 INSTRUCTIONS FOR USE........................................................................... 76 ROAD TRAVEL ............................................................................................. 77 JOB SITE TRAVEL........................................................................................ 79 LOADER OPERATING INSTRUCTIONS...................................................... 79 SERVICING INTERVALS ............................................................................ 82 - 86 SERVICING INSTRUCTIONS ....................................................................... 82 HOURMETER................................................................................................ 83 SERVICING INTERVALS .............................................................................. 84

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LUBRICATION/FILTERS/FLUIDS ............................................................. 88 - 124 FLUIDS AND LUBRICANTS.......................................................................... 88 ENVIRONMENT ............................................................................................ 90 PLASTIC AND RESIN PARTS ...................................................................... 90 FLUID AND LUBRICANT CAPACITIES AND SPECIFICATIONS ................ 91 GREASE POINTS ......................................................................................... 92 LEVELS ......................................................................................................... 98 ENGINE ....................................................................................................... 101 COOLING SYSTEM .................................................................................... 103 FUEL SYSTEM............................................................................................ 106 AIR FILTER ................................................................................................. 109 CAB VENTILATION INLET FILTER ............................................................ 112 HYDRAULIC SYSTEM ................................................................................ 113 AXLES AND REDUCTION GEARS............................................................. 117 BRAKES ...................................................................................................... 123 MAINTENANCE/ADJUSTMENTS........................................................... 125 - 143 WHEELS AND TYRES ................................................................................ 125 RADIATOR AND OIL COOLER................................................................... 127 ENGINE ALTERNATOR AND FAN BELT ................................................... 128 ADJUSTING THE ENGINE VALVE ROCKER CLEARANCES ................... 131 CHECKING AND CLEANING THE MACHINE ............................................ 131 CHANGING A BUCKET TOOTH TIP .......................................................... 131 TOOTH WEAR LIMITS................................................................................ 132 CHANGING A BUCKET .............................................................................. 132 CHANGING A 4-IN-1 BUCKET ................................................................... 134 CHECKING THE CYLINDERS FOR LEAKS............................................... 137 TROUBLESHOOTING................................................................................. 138

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SPECIFICATIONS ................................................................................... 160 - 167 ENGINE ....................................................................................................... 160 ELECTRICAL SYSTEM ............................................................................... 160 SOUND LEVELS ......................................................................................... 160 TRANSMISSION.......................................................................................... 161 AXLES ......................................................................................................... 161 TYRES ......................................................................................................... 161 BRAKES ...................................................................................................... 162 STEERING................................................................................................... 162 HYDRAULIC SYSTEM ................................................................................ 163 CAPACITIES................................................................................................ 163 PERFORMANCE AND SPECIFICATIONS ................................................. 164 STANDARD OR OPTIONAL ACCESSORIES............................................. 166 MACHINE OVERALL DIMENSIONS AND WORKING RANGE .................. 167

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STORAGE................................................................................................ 158 - 159 STORING THE MACHINE........................................................................... 158

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ELECTRICAL SYSTEM........................................................................... 144 - 157 FUSES ......................................................................................................... 144 STARTER MOTOR FUSE ........................................................................... 146 BATTERY .................................................................................................... 147 CONNECTING A BOOSTER BATTERY ..................................................... 150 ALTERNATOR............................................................................................. 151 STARTER MOTOR...................................................................................... 151 INJECTORS................................................................................................. 152 BULBS ......................................................................................................... 152 REPLACING A BULB .................................................................................. 153 ADJUSTING THE HEADLIGHTS ................................................................ 157

Template Name: OM_1_col Template Date: 1994_04_29

ALPHABETICAL INDEX ......................................................................... 168 - 170

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TO THE OWNER

Dealer’s stamp

Case France Rue des Meuniers 60330 Le Plessis-Belleville FRANCE

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Alt= to hide template information Alt+ to display template information Template Name: OM_1_col Template Date: 1994_04_29

CD97E041

Series shown : 221B

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121B AND 221B SERIES WHEEL LOADERS

TO THE OWNER

TO THE OWNER Template Name: OM_1_col Template Date: 1994_04_29

You are the owner of a machine that has been designed and built with quality constantly in mind. It is in conformity with current regulations on safety at work and on the road in accordance with each country’s national regulations. (See “Official documents”). However, this does not exclude all risk of accidents; that is why it is essential to observe elementary safety rules and precautions.

Read this manual carefully before operating the machine. Instructions concerning safety, operation and maintenance have been developed to permit safe service and operation of this machine.

Use this manual as a guide. Your machine is a working tool which you will always be able to count on, as long as it is correctly maintained.

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The machine's standard attachments and tools are intended for carrying out all types of earthmoving, handling, etc. work.

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Do not use this machine for any applications or purposes other than those described in this manual. If you use this machine for work requiring special attachments or tools, consult your CASE Dealer to make sure that the adaptations or modifications to be carried out are in conformity with the technical specifications of the machine and that they are in accordance with current safety regulations.

Any modifications or adaptations which are not approved by the manufacturer may invalidate the machine's original conformity with safety requirements.

For certain applications, the machine must undergo regular inspection. Consult your CASE Dealer.

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TO THE OWNER

He has received necessary training on how to operate the machine correctly and safely in one of our Training Centres or from an approved organization.

2.

He has read and fully understood the instructions given in this manual.

Always keep this manual in the storage compartment provided for it. Make sure that it is always complete and in good condition. Consult your CASE Dealer to obtain extra manuals or manuals in other languages.

Official documents Standard test certificate - Noise level (86/662/EEC) (copy provided in separate form or on the back of the EC declaration of conformity) EC declaration of conformity - For a new construction equipment machine, series produced in accordance with the approved standard and designed and built to meet the requirements of European Directive 89/392 covering the safety of machinery, with particular reference to : 1

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- The following directives: - 86/662 EEC: Noise level - 89/336 EEC: Electromagnetic compatibility - The following European standards: - EN 474 - 1: Safety - General requirements - EN 474-3 : Safety - Loaders

IMPORTANT : An original of this “EC” conformity declaration is supplied with every machine and must be kept carefully by the owner. (Only a photocopy can be supplied later on request, a copy certified as being in conformity which will be charged for).

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Your CASE Dealer is at your disposal for any further information.

He is also available to provide any after-sales service you may require and to supply you with genuine CASE parts, your only guarantee of interchangeability and quality.

Template Name: OM_1_col Template Date: 1994_04_29

1.

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Before entrusting this machine to an operator, make sure that :

TO THE OWNER

PRESENTATION Template Name: OM_1_col Template Date: 1994_04_29

The 121B and 221B loaders are hydraulic earthmoving machines. They consist of travel components, an engine, hydraulic assemblies and an operating compartment. When the operator operates the controls, the pump, which is driven by the engine, sends hydraulic fluid to the control valves. The control valves distribute the hydraulic fluid to the various components. A cooling system including an oil cooler maintains the hydraulic fluid at normal operating temperature.

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TO THE OWNER

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1

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2 PDH0437

1 FRONT 2 REAR

3 RIGHT-HAND SIDE 4 LEFT-HAND SIDE

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Template Name: OM_1_col Template Date: 1994_04_29

The terms "right", "left", "front" and "rear", when used in this manual, indicate the sides of the machine as seen from the operator’s seat.

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RIGHT, LEFT, FRONT AND REAR OF THE MACHINE

IDENTIFICATION NUMBERS/MACHINE COMPONENTS

TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE Template Name: OM_1_col Template Date: 1994_04_29

When ordering parts, requesting information or assistance, always give your CASE Dealer the type and serial number of your machine.

Write the type, serial number and year of manufacture of your machine and the serial numbers on the various hydraulic and mechanical components in the spaces provided below.

Machine

Special for Germany

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3 CS97F044

CD97E010

(1) Type................................................. ..............................................................

(2) Serial number ..................................

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..............................................................

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(3) Year of manufacture ........................ ..............................................................

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CS97F043

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IDENTIFICATION NUMBERS/MACHINE COMPONENTS

ROPS/FOPS cab (or frame) 4 1 5 2

CD97E002

(4) Make and type .....PERKINS 704-30

CD97E003

(5) Serial number ..................................

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Component serial numbers Hydraulic pump ..................................... ..............................................................

Front drive axle .....................................

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..............................................................

Rear axle............................................... ..............................................................

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Engine

CD97E012

Drop box................................................ ..............................................................

..............................................................

Attachment travel control valve .............

(2) Maximum machine weight ...............

..............................................................

..............................................................

Hydraulic motor .....................................

(3) In conformance with ROPS : ISO 3471-1 and EN 474-3 FOPS : ISO 3449 and EN 474-3

..............................................................

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Template Name: OM_1_col Template Date: 1994_04_29

(1) ROPS /FOPS serial number............

IDENTIFICATION NUMBERS/MACHINE COMPONENTS

Axle Template Name: OM_1_col Template Date: 1994_04_29

The axle is identified by a cold-stamped identification number.

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(1) AB : Axle with limited slip differential (2) Torque ratio

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(3) Month/Year of manufacture

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CD97F019

IDENTIFICATION OF THE MAIN COMPONENTS

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4 CD97E041

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Loader bucket Loader arm Front drive axle Fuel tank Rear axle Cab/Operator’s compartment Engine hood Battery box Hydraulic reservoir

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SAFETY/DECALS/HAND SIGNALS

Your safety and that of people around you depends on you. It is essential that you understand this manual for the correct operation, inspection, lubrication and maintenance of this machine.

Read this manual carefully and check that : - You understand fully the symbols on the controls and the safety signs used in this manual and on the machine.

- You understand fully the speed, stability, braking and steering characteristics of the machine. If you are in any doubt, consult your CASE Dealer.

Whatever type of work is concerned (earthmoving, handling, etc.), the safety arrangements applicable to private or public job sites are those which correspond to the regulations in force in the country and in the trade concerned (example : mining, quarries, underground work).

The information given in this chapter is a summary of the basic rules to respect at all times and does not exempt you from observing traffic regulations or the requirements of insurance companies.

Template Name: OM_1_col Template Date: 1994_04_29

Always keep this manual in the storage compartment provided for it. Make sure that it is always complete and in good condition. Consult your CASE Dealer to obtain extra manuals.

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The safety messages in this section concern situations which may arise during normal machine operation and servicing. These safety messages also indicate the different ways of coping with these situations. Other safety messages are used throughout the manual to indicate specific dangers.

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SAFETY RULES

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SAFETY/DECALS/HAND SIGNALS

BEFORE USING THE MACHINE Template Name: OM_1_col Template Date: 1994_04_29

On road and job site • Read and assimilate the instructions • and warnings shown in this manual before operating the machine.

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The presence of grease, oil, mud or (in winter) ice on the steps and access handles can cause accidents. Make sure they are always clean.

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Remove anything which can hinder visibility. Clean the windows and rear view mirrors.

Before travelling or working at night, check that the lighting and signalling systems are operating correctly.

Before undertaking any travel, make sure that the doors, engine hood and front panel are all correctly fastened.

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Make sure that no loose object or tool is left on the machine or in the operator’s compartment.

The operator must be alone on the machine. Make sure there is nobody on or near the machine.

When mounting or dismounting from the machine always face the machine and use the steps and access handles on the left-hand side of the machine.

The right-hand door is to be used only in case of emergency.

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Make sure you know the location and function of every control. Operating the controls wrongly can cause serious physical injury.

Be ready for emergencies. Always keep a first aid kit and a fire extinguisher close at hand on the machine. Make sure that the fire extinguisher is maintained in accordance with the manufacturer’s instructions.

Make sure that you fully understand the location and function of each control. An incorrect manipulation of the controls can cause serious physical injury.

Always fasten your seat belt before starting the engine. The machine is equipped with a roll over protection system (ROPS) which ensures your safety. The seat belt will protect you effectively if you attach it correctly and if you always wear it. The seat belt should not be too loose. It must not be twisted or caught in the seat.

Regularly check the condition and pressure of the tyres.

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cab doors are closed correctly before undertaking any road travel.

Before undertaking any road travel, lock the working attachments and install the safety systems required by regulations.

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On the job site • Operating the machine

requires your full attention. Caution on the part of the operator can avoid accidents. Make sure you are aware of the machine’s possibilities, its limits and the space required for it to be operated. There are areas of poor visibility in the working area of the machine. Have someone guide you for any work where good visibility is not available.

Check that all the controls and all the safety devices operate correctly in a safe, clear area before beginning work.

Keep away from dangerous areas such as ditches, over-hangs, soft areas, etc.. Walk around the work site before using the machine and look for hazards.

Inspect and note all possible risks before driving the machine into a new working area. Holes, obstacles, debris and other hazards in the working area can cause serious physical injury.

Check all around the machine every day to ensure there are no oil leaks or hydraulic fluid leaks. Tighten unions as necessary and replace any parts as required.

Template Name: OM_1_col Template Date: 1994_04_29

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Make sure you know the hand signals used on your job site so that you can be guided when making delicate manoeuvres or for work where direct visibility is not available.

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Road operation • Check that both the

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SAFETY/DECALS/HAND SIGNALS

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SAFETY/DECALS/HAND SIGNALS

OPERATING THE MACHINE Template Name: OM_1_col Template Date: 1994_04_29

On road and job site • Do not allow anyone to climb onto the • machine. A passenger could fall or cause an accident.

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Never operate a working or driving control unless you are correctly seated in the operator’s seat.

Adapt your operating style to the working conditions (sloping or rough ground) and to road and weather conditions.

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Operate all the controls gradually so the machine functions smoothly.

Stop the engine and remove the starter key even for short stops.

Never leave the operator's compartment when the engine is running.

To enter of leave the operator’s compartment, it is essential that the attachment controls are locked. Never try to by-pass this basic safety requirement.

Dust, smoke or fog can reduce visibility and cause an accident. Stop the machine or slow down until visibility returns to normal.

Never jump down from the machine.

When dismounting from the machine always face the machine and use the steps and access handles.

Whenever parking the machine on sloping ground, use the wheel chocks to immobilize the machine (optional).

Never travel at full speed with the attachment completely raised.

Do not travel at high speed if the bucket hinders visibility. You may hit some hidden object.

On the job site • When working on a

job site on the public highway, use regulation signs, taking the working area into account.

National or local regulations define the number, type and location of reflective strips.

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Avoid running the engine in an enclosed space. If this cannot be avoided, make sure there is good ventilation in all circumstances.

Never work close to a live overhead electrical line unless you have first made sure that the minimum distances are being observed: Under 57,000 volts : 3 meters.

Over 57,000 volts : 5 meters.

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Do not allow anyone to stand in the machine working area. If the operator uses the swing or attachments controls wrongly, this could cause an accident. Stop all movement until the person has moved away.

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When moving a machine onto a trailer, position the speed selector in first speed (position 1). Keep the loader bucket 20 cm above the ground.

If there is an operating problem or some damage, move the machine to a safe place, immediately lower the attachment to the ground, remove the starter switch key and apply the parking brake lever. Locate or report the failure and, if necessary, take steps to prevent the use of the machine.

When the machine is being lifted, nobody must be allowed to remain in the area surrounding the machine.

Template Name: OM_1_col Template Date: 1994_04_29

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Make sure you know the location of pipes and cables before starting work.

Electrical cables, gas pipes, water pipes or other underground installations can cause serious physical injury.

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SAFETY/DECALS/HAND SIGNALS

PARKING THE MACHINE • Template Name: OM_1_col Template Date: 1994_04_29

When you park your machine, proceed in the following manner:

5. Stop the engine and remove the starter switch key.

1. Park the machine on flat, level ground, away from soft ground, an excavation or a badly shored cavity.

6. Release the hydraulic pressure by operating the control levers in both directions.

2. Place the bucket pressing on the ground.

7. Lock the attachment controls.

3. Place the direction of travel selector in the neutral position (N).

4. Immobilize the machine by means of the parking brake lever.

8. Make sure that the doors, engine hood and the front panel are correctly fastened and lock the operator’s compartment doors.

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9. Make sure that no part of the machine is protruding onto the public highway.

If this cannot be avoided, install signs in accordance with regulations. If this cannot be avoided, install signs in conformity with regulations.

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SAFETY/DECALS/HAND SIGNALS

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When servicing the machine, wear suitable, close-fitting clothing.

When servicing the machine, place the “Do not start up” label on the instrument panel (supplied with the machine).

Always wear eye protection when using a tool which might project metal particles. Use a hammer with a soft face, such as copper, for installing pins.

Incorrectly performed maintenance or adjustments can cause serious physical injury. If you do not understand a maintenance or adjustment procedure, consult your CASE Dealer.

If the attachment is in the raised position or the machine moves when there is no operator at the controls serious injury can result. Before carrying out any maintenance operation on this machine, proceed in the following manner:

1. Park the machine on flat, level ground.

2. Lower the attachment until it is resting on the ground.

3. Shut down the engine and remove the starter switch key.

4. Raise the parking brake lever.

5. Lock the attachment controls.

6. Lock the wheels to prevent all machine movement.

If a servicing operation requires the attachment to be raised, install the attachment locking system.

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Unauthorized modifications to the machine can cause serious physical injury. Do not carry out any modification on this machine without the prior authorization of your CASE Dealer.

All modifications carried out must be in conformity with the machine’s technical specifications and must conform to current safety regulations.

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Template Name: OM_1_col Template Date: 1994_04_29

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Do not carry out any maintenance work until you have read and assimilated the instructions and warnings shown in this manual.

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MAINTENANCE AND ADJUSTMENTS

SAFETY/DECALS/HAND SIGNALS

• Template Name: OM_1_col Template Date: 1994_04_29

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Do not carry out any welding operation on the machine without prior authorization from your CASE Dealer.

Certain components of the machine are subject to type approval. When they are replaced it is mandatory to ensure that they are in conformity with regulations. For safety’s sake, always use genuine CASE parts.

Hydraulic fluid or grease under pressure which penetrates the skin can cause serious physical injury. Take the necessary safety measures (protective clothing and accessories for the face and hands) to prevent all such risks. In addition, before handling any of these products, read the manufacturer’s specific instructions for their use. If hydraulic fluid penetrates the skin, a doctor must be consulted immediately.

When carrying out a welding operation on the machine, as authorized by the manufacturer and in accordance with his specifications, disconnect the alternator plug and connect the welding set earth lead to the component on which the welding is to be carried out. Never connect the earth lead to a hydraulic system component.

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When checking pressures or during an inflation operation, never position yourself opposite the tyre but always facing the tread surface. Always use an inflation cage when the wheel is removed from the machine. Keep all other persons away from the area.

Never weld near a tyre. It is essential to remove the tyre before any welding operation.

When using compressed air take the necessary measures to protect your face.

The machine’s structure is in conformity with the “FOPS” and “ROPS” protection standards. Any modification (drilling, welding, etc.) may cause that conformity to be cancelled.

Replace the ROPS/FOPS cab (or protective structure) if it has undergone an impact or if the machine has turned over. Do not try to repair it.

A burst tyre can cause serious injury.

Regularly check the condition of tyres and always observe the inflation pressures defined in accordance with the type of tyre and ground concerned.

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PREVENTION OF FIRE OR EXPLOSION • Engine fuel can cause an explosion or • The machine’s

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Use a non-inflammable product for cleaning parts.

A spark or flame can cause the hydrogen in a battery to explode. To prevent any risk of explosion, observe the following instructions : - When disconnecting the battery cables, always disconnect the negative (-) cable first.

- When reconnecting the battery cables, always connect the negative cable (-) last.

- Never short-circuit the battery terminals with metal parts.

- Put the terminal covers back in place during any maintenance operation.

- Do not weld, grind or smoke near a battery.

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Always keep a fire extinguisher available on the machine. Make sure that it is properly maintained in conformity with the manufacturer’s instructions.

Clean the machine regularly, remove all debris and material which may catch fire.

Check for leaks. Replace damaged hoses, pipes and unions. Clean the machine after any repair work before operating it.

Template Name: OM_1_col Template Date: 1994_04_29

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electrical system or exhaust system can emit sparks.

Make sure that adequate ventilation is provided before running the machine in an area where there may be inflammable vapours.

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a fire.

- Never fill the fuel tank when the engine is running.

- Never smoke during refuelling.

- Take all necessary safety measures when welding or grinding or when you are near a flame.

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SAFETY/DECALS/HAND SIGNALS

PREVENTION OF BURNS • Template Name: OM_1_col Template Date: 1994_04_29

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Battery electrolyte causes severe burns. The battery contains sulphuric acid. Avoid all contact with the skin, the eyes or clothing.

Antidote : EXTERNAL : Rince with water.

INTERNAL : Drink large quantities of water or milk. Then drink milk of magnesia, a beaten egg or vegetable oil.

Call a doctor immediately.

EYES : Rinse with water for 15 minutes and call a doctor quickly.

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When the electrolyte of a battery is frozen, it can explode if you attempt to charge the battery or if you try to start the engine using a booster battery.

Always keep the battery charged to prevent the electrolyte freezing.

A battery produces explosive gases.

Keep all flames, sparks and cigarettes away. Ventilate when changing a battery or using a battery in an enclosed space. Always protect your eyes when working close to a battery.

Boiling coolant solution can spray out if the radiator cap is removed while the system is still hot. Before removing the cap, allow the system to cool down, then turn the cap to the first notch and wait until all pressure is released. Then remove the cap.

ROPS/FOPS CAB (or frame) •

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Do not try to weld or straighten the ROP/FOPS cab (or frame).

Do not modify the ROPS/FOPS cab (or frame) in any manner. Unauthorized modification, such as welding, drilling, cutting and adding attachments, as well as any damage resulting from collisions or the machine rolling over could weaken the structure and reduce your protection. Replace the ROPS/FOPS cab (or frame) if subjected to roll over or damage. Do not attempt to repair it.

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If you operate this machine without a ROPS/FOPS cab (or frame) and the machine rolls over, you can be seriously injured or killed. Remove the ROPS/FOPS cab only for service or replacement. Do not operate the machine with the ROPS/FOPS cab (or frame) removed.

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Do not install accessories (fastened or otherwise) which could increase the weight of the machine. Serious accidents could result. Do not exceed the maximum weight shown on the ROPS/ FOPS cab (or frame) identification plate).

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Improper ROPS/FOPS cab (or frame) inspection or maintenance can cause serious injury. Carry out the recommended ROPS/FOPS cab (or frame) inspection procedure shown in this manual. If it is necessary to replace ROPS/FOPS parts or the ROPS/ FOPS cab (or frame), use only the replacement parts shown in the Parts Catalogue for your machine.

Template Name: OM_1_col Template Date: 1994_04_29

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•

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SAFETY/DECALS/HAND SIGNALS

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SAFETY/DECALS/HAND SIGNALS

DECALS Template Name: OM_1_col Template Date: 1994_04_29

WARNING : An illegible or missing decal can have far-reaching consequences. Check them everyday.

WARNING : Make sure that decals are perfectly legible, clean them regularly and replace them with new decals if they are damaged, missing or painted over. If there is a decal on a part that is replaced, make sure you install a new decal on the new part.

NOTE : You can obtain new decals from your CASE Dealer; the Part Numbers are shown in the parts catalogue.

NOTE : This chapter concerns only those decals connected with safety, operation and maintenance of the machine. To see all the decals which exist on the machine, consult the spare parts catalogue.

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IMPORTANT : When replacing a decal, make sure you replace it in the same position as the original decal.

External noise level

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CD97E003

CS97E023

Part number : H4951585 This decal shows the value in decibels of the external noise level of the machine, as guaranteed by the manufacturer. In accordance with European directive 86/662/EEC.

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SAFETY/DECALS/HAND SIGNALS

CD97E003

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CD97E020

CS97E022

Part number : G4951584 This decal shows the value in decibels of the internal noise level in the operator’s compartment, as guaranteed by the manufacturer. In accordance with European directive 86/662/EEC.

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Keep clear of the attachment working area

CS97E006

Part number : 285723A1 This decal shows that it is forbidden to enter the attachment working area without having installed the safety system

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Template Name: OM_1_col Template Date: 1994_04_29

Internal noise level

SAFETY/DECALS/HAND SIGNALS

Keep clear of the working area

Filling the fuel tank

Template Name: OM_1_col Template Date: 1994_04_29

CD97E006 CD97E004

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CS97E011

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CS97E008

Part number : 285724A1 This decal shows that the operator must not allow any person in the machine’s working area when the engine is running

Part number : 285721A1 This decal shows the location of the fuel tank.

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SAFETY/DECALS/HAND SIGNALS

Towing

CD97E013

CS97E012

PDH0425

Part number : 219652A1 This decal shows that towing the machine is a delicate operation which is described in this manual. See “Towing” in the “Operating Instructions” Section.

Template Name: OM_1_col Template Date: 1994_04_29

Part number : 285732A1 This decal shows the instructions for closing the cab doors.

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CD97E005

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Closing the cab doors

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SAFETY/DECALS/HAND SIGNALS

Filling the hydraulic fluid reservoir

Opening the engine hood

Template Name: OM_1_col Template Date: 1994_04_29

CD97E009 CD97E007

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PDH0426

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CS97E009

Part number : 285728A1 This decal shows the location of the hydraulic reservoir.

Part number : E129712 This decal shows that the engine must be shut down before opening the engine hood.

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SAFETY/DECALS/HAND SIGNALS

Sling points

CD97E010

CS97E007

PDE0768

Part number : H7947565 This decal shows the sling points to be used when lifting the machine. Never use any sling point other than those shown by this decal.

Template Name: OM_1_col Template Date: 1994_04_29

Part number : 285726A1 This decal shows that the operator must not allow any person in the machine’s articulation area when the engine is running.

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CD97E008

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Central pivot

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SAFETY/DECALS/HAND SIGNALS

Non sling points

Battery

Template Name: OM_1_col Template Date: 1994_04_29

CD97E067

CD97E011

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PDE0769

CS97E005

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Part number : X351599 This decal shows the points of the machine where slings must not be attached. These points may under no circumstances be used to handle the machine.

Part number : 285721A1 This decal shows that the operator’s manual must be consulted. See “Battery” in the “Electrical System” Section.

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SAFETY/DECALS/HAND SIGNALS

Anti-freeze

CD97E013

CS97E010

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CD97E012

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Safety instructions

CS97F033

Part number : 321-6706 This decal shows the safety rules to be observed before and after using the machine. See “Before using the machine” and “Operating the machine” in the “Operating Instructions” Section.

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Template Name: OM_1_col Template Date: 1994_04_29

Part number : 285730A1 This decal shows that the cooling system contains anti-freeze.

SAFETY/DECALS/HAND SIGNALS

Attachment control function

Do not put your foot here

Template Name: OM_1_col Template Date: 1994_04_29

CD97E010 CD97E014

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CS97F032

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PDH0432

Part number : 217130A1 This decal shows the function of the attachment control lever.

Part number : E134402 This decal shows that it is forbidden to climb at this location.

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SAFETY/DECALS/HAND SIGNALS

Maximum speed (special for Germany)

CD97E041

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CD97E034

PDG0077

Part number : 217126A1 This decal shows that the machine’s articulation functions only when the engine is running.

Part number : L1751552 This decal shows that the maximum speed authorized on the public highway is 20 kph.

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Template Name: OM_1_col Template Date: 1994_04_29

PDH0433

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Machine articulation (special for Germany)

SAFETY/DECALS/HAND SIGNALS

HAND SIGNALS Template Name: OM_1_col Template Date: 1994_04_29

When operating the machine, never attempt to carry out tasks calling for fine control or to work in areas where visibility is poor or impaired without seeking the assistance of a signalman. Make perfectly sure that you and the signalman understand the signals to be used.

Start engine

Shut down engine

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PDE0002A

PDE0002

Come to me

Move away from me

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PDE0003A

PDE0003

Move hands forward and rearward (palms in).

Move hands forward and rearward (palms out).

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SAFETY/DECALS/HAND SIGNALS

PDE0004A

PDE0004

Emergency stop

PDE0005A

PDE0005

Move one hand palm down back and forth.

Move both hand palms down rapidly back and forth.

Raise load or tool

Lower load or tool

PDE0006A

PDE0006

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Stop

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All stop and hold

Template Name: OM_1_col Template Date: 1994_04_29

Go this far

SAFETY/DECALS/HAND SIGNALS

Slowly raise load or tool

Slowly lower load or tool

Template Name: OM_1_col Template Date: 1994_04_29

PDE0007A

PDE0007

Turn machine left (swing load left)

Turn machine right (swing load right)

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PDE0008A

PDE0008

To stop movement, stop moving hand and make a fist.

To stop movement, stop moving hand and make a fist.

Raise bucket

Dump bucket

PDE0009A

PDE0009

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Template Name: OM_1_col Template Date: 1994_04_29

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This page is intentionally left blank

CONTROLS/INSTRUMENTS/ACCESSORIES

CAB DOORS Closing

Opening Template Name: OM_1_col Template Date: 1994_04_29

1 2

CD97E015

CD97E016

The doors are opened from the outside by pressing button (1). They are kept in the open position by a latch.

To unlatch the doors, pull the corresponding handle forwards.

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NOTE : The doors can be locked by means of a key.

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CD97E035

The doors are opened from the inside by pulling the corresponding handle.

WARNING : Do not leave the doors ajar. Fasten them in a latched position.

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CONTROLS/INSTRUMENTS/ACCESSORIES

CD97E018

WARNING : Never use the steering wheel, the attachment control levers or the parking brake lever to help you enter or leave the operator’s compartment.

WARNING : Clean the steps and access handles and remove all traces of grease, oil, mud and ice (winter).

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CD97E017

To enter or leave the operator’s compartment, use the steps and access handles on the left-hand side of the machine. The right-hand door is to be used only in case of emergency.

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STEPS AND ACCESS HANDLES

Template Name: OM_1_col Template Date: 1994_04_29

WARNING : Never jump down from the machine. When dismounting from the machine always face the machine and use the steps and access handles.

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CONTROLS/INSTRUMENTS/ACCESSORIES

MONITORING PANEL Template Name: OM_1_col Template Date: 1994_04_29

9

1

2

3

4

5 8 7 6

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CK97E001

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1. ENGINE GREEN SYMBOL - This symbol lights up and the audible warning device sounds when the following warning lamps come on: engine water temperature (9), engine oil pressure (8) or air filter (7). If this symbol lights up when the machine is operating, move the machine to a safe place, shut down the engine immediately, remove the starter switch key and locate the source of the problem.

2. TRANSMISSION ORANGE SYMBOL - This symbol lights up and the audible warning device sounds when the following warning lamps come on: transmission oil temperature (4) or transmission oil pressure (5). If this symbol flashes while the machine is operating, move the machine to a safe place, shut down the engine immediately, remove the starter switch key and locate the source of the problem.

3. AUDIBLE WARNING DEVICE CUT-OUT PUSH-BUTTON - Press this button to cancel out the audible warning device. The indicator lamp corresponding to the problem stays on.

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6. BATTERY RED WARNING LAMP - This warning lamp comes on and the audible warning sounds when the alternator is not charging the battery (slack or broken alternator drive belt, defective alternator or battery, etc.). If the warning lamp comes on when the machine is operating, move the machine to a safe place, shut down the engine immediately, remove the starter switch key and locate the source of the problem.

7. ENGINE AIR FILTER RED WARNING LIGHT - This warning light comes on, the audible warning device sounds and the engine green symbol (1) lights up when the air filter is restricted. Clean or change the filter element. See "Air filter" in the "Lubrication/Filters/Fluids" Section.

8. ENGINE OIL PRESSURE RED WARNING LAMP - This warning lamp comes on, the audible warning device sounds and the green engine symbol (1) lights up when the engine oil pressure is too low. If the warning lamp comes on when the machine is operating, move the machine to a safe place, shut down the engine immediately, remove the starter switch key and locate the source of the problem.

9. ENGINE COOLANT SOLUTION TEMPERATURE RED WARNING LAMP This warning lamp comes on, the audible warning device sounds and the engine green symbol (1) lights up when the engine cooling system reaches an abnormally high temperature. If the warning lamp comes on when the machine is operating, move the machine to a safe place, shut down the engine immediately, remove the starter switch key and locate the source of the problem (fan operating failure, lack of coolant solution in the system, a leak, etc.). See "Cooling system" in the "Lubrication/Filters/Fluids" Section".

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5. TRANSMISSION OIL FILTER RED WARNING LAMP - This warning lamp lights up, the audible warning device sounds and the transmission red symbol (2) lights up when the transmission oil filter is restricted. If the warning lamp comes on when the machine is operating, move the machine to a safe place, shut down the engine immediately, remove the starter switch key and change the filter. See “Hydraulic transmission oil filter” in the “Lubrication/Filters/Fluids” Section”.

Template Name: OM_1_col Template Date: 1994_04_29

4. TRANSMISSION OIL TEMPERATURE RED WARNING LAMP - This warning lamp comes on, the audible warning device sounds and the transmission red symbol (2) lights up when the transmission oil temperature is too high. If the warning lamp comes on when the machine is operating, move the machine to a safe place, shut down the engine immediately, remove the starter switch key and locate the source of the problem.

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CONTROLS/INSTRUMENTS/ACCESSORIES

CONTROLS/INSTRUMENTS/ACCESSORIES

CONTROL PANEL Template Name: OM_1_col Template Date: 1994_04_29

1 6

7

2

3

4

11

9 5

12 13 8

10 14 15

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CK97E002

1. SPEED SELECTOR POSITION GREEN INDICATOR LAMP - This indicator lamp comes on when the speed selector is in the neutral position (position N).

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2. SPEED SELECTOR POSITION YELLOW INDICATOR LAMP - This indicator lamp comes on when the speed selector is in the job site forward or reverse travel position (position 2 or 4).

3. SPEED SELECTOR POSITION YELLOW INDICATOR LAMP - This indicator lamp comes on when the speed selector is in the road forward or reverse travel position (position 3 or 5).

4.

Not used.

5.

Not used.

6. DIRECTION INDICATOR GREEN INDICATOR LAMP - This indicator lamp comes on when the direction indicator control or the hazard warning light control is operated and flashes at the same frequency as the direction indicators. If the indicator lamp does not flash, one of the direction indicator lamps is defective.

NOTE : To replace a bulb see “Replacing a bulb” in the “Electrical System” Section.

7. SIDE LIGHT AND DIPPED HEADLIGHT GREEN INDICATOR LAMP - This indicator lamp comes on when the lighting switch is in the sidelight, dipped headlight or main-beam headlight position.

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CONTROLS/INSTRUMENTS/ACCESSORIES

9. BRAKE SYSTEM PRESSURE RED WARNING LAMP - This warning lamp comes on when the brake system supply pressure is insufficient. If the warning lamp comes on when the machine is operating, move the machine to a safe place, shut down the engine immediately, remove the starter switch key and locate the source of the problem.

This warning lamp can be checked by pressing the brake fluid reservoir blue capsule.

CD97E033

10. PARKING BRAKE RED WARNING LAMP - This warning lamp comes on and the audible warning device sounds when the parking brake lever is pulled upwards and the direction of travel selector is not in the neutral position (position N).

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NOTE : If the warning lamp does not come on, replace the lamp bulb. See "Replacing a bulb" in the "Electrical System" Section.

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8. MAIN-BEAM HEADLIGHT BLUE INDICATOR LAMP - This indicator lamp comes on when the main-beam or dipped headlight/main-beam headlight flasher control is operated.

12. Not used.

13. Not used.

14. ENGINE PRE-HEATING ORANGE INDICATOR LAMP - This indicator lamp comes on when the starter switch key is in the pre-heat position.

15. Not used.

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Template Name: OM_1_col Template Date: 1994_04_29

11. STEERING PRESSURE RED WARNING LAMP - This warning lamp comes on when the hydraulic pressure in the steering system is insufficient. If the warning lamp comes on when the machine is operating, move the machine to a safe place, shut down the engine immediately, remove the starter switch key and locate the source of the problem.

CONTROLS/INSTRUMENTS/ACCESSORIES

CONTROL SWITCHES Template Name: OM_1_col Template Date: 1994_04_29

1. HAZARD WARNING LIGHT CONTROL - When the switch is tilted to the rear, it flashes and the direction indicator lights and the direction indicator green indicator lamp (6) on the instrument panel flashes simultaneously.

2 1

2. FRONT WINDSHIELD WIPER AND WINDSHIELD WASHER CONTROL - When the switch is tilted to the rear in the first position, the windshield wiper works. When the switch is held in the second position, the windshield washer works. When pressure on the switch is released, the control returns automatically to the first position.

CD97E032

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3

4

5

3. FRONT WORKING LIGHT CONTROL - When the switch is tilted downwards, it lights up and the front working lights come on if the side lights, dipped headlights or main-beam headlights are on.

6

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4. ROTARY LIGHT CONTROL When the switch is tilted downward, it lights up and the rotary light operates.

CK97E004

5. REAR WINDSHIELD WIPER AND WINDSHIELD WASHER CONTROL When the switch is tilted downward, in the first position, the windshield wiper works. When it is held in the second position, the windshield washer works. When the pressure on the switch is released, the switch returns automatically to the first position.

6. REAR WORKING LIGHT CONTROL - When the switch is tilted downward, it lights up and the rear working light comes on if the sidelights, dipped headlights or main-beam headlights are on.

NOTE : In cold weather, add anti-freeze to the water in the windshield washers.

NOTE : To replace a bulb in the working lights, rotary light or hazard warning lights, see “Replacing a bulb” in the “Electrical System” Section.

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CONTROLS/INSTRUMENTS/ACCESSORIES

1

Fuel level gauge 2

3

CK97E002

Located on the control panel.

1. Off. 2. On and pre-heat 3. Start.

CD97E032

NOTE : The “Start” position can only be used if the gear selector is in the neutral position.

Located above the control switches, this gauge shows the fuel level. The gauge is illuminated when the sidelights are on.

Hourmeter and speedometer

2

1 CK97E002

Located above the control panel, the hourmeter (1) is used to determine the servicing intervals.

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Key positions:

Template Name: OM_1_col Template Date: 1994_04_29

the engine is running and the speedometer (2) shows the machine’s travel speed in kph. The speedometer is illuminated when the sidelights are on.

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OPERATOR’S COMPARTMENT CONTROLS Starter switch It works in the same way as a clock when

CONTROLS/INSTRUMENTS/ACCESSORIES NOTE : The engine cannot be started unless the gear selector is in the neutral position.

Speed selector and audible warning device Template Name: OM_1_col Template Date: 1994_04_29

6 3 1

NOTE : An audible warning device sounds when the selector is in reverse travel.

2

Direction indicator and road light control

1 4

5

5 CD97E036

2

Located above the steering column, this control has six positions: TRIM THIS EDGE

1. Neutral.

2. Job site forward travel.

3. Public highway forward travel.

4. Job site reverse travel.

5. Public highway reverse travel 6. Horn control (momentary operation control).

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NOTE : It is possible to change from position (2) to position (3) or from position (4) to position (5) without passing through position (1).

NOTE : Maximum permitted speeds for the machine are as follows: - 9 kph for job site travel.

- 24 kph for public highway travel.

- 20 kph (special for Germany).

4 1

3 PH02617

Located on the right-hand side of the steering column, this control has five positions.

1. Off. 2. The left-hand direction indicators flash.

3. The right-hand direction indicators flash.

4. Dipped headlight or main-beam headlight flash (momentary action control).

5. Dipped headlight/main-beam headlight selection for flash and for lighting control (momentary action control) (See “Lighting control”).

IMPORTANT : Stop the machine completely before changing the direction of travel.

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CONTROLS/INSTRUMENTS/ACCESSORIES

1 2 3 4 PH02617

CK97E005

1. Off. 2. Sidelights.

3. Dipped headlights.

4. Dipped headlights or main-beam headlights (depending on operation of headlight control) (See “Direction indicator and main-beam headlight control”).

The machine's travel speed depends on the extent to which the pedal is tilted.

NOTE : The speed also depends on the speed range which has been selected.

See “Speed selector”.

Brake pedal

CK97E006

The brake pressure depends on the pressure exerted on the brake pedal.

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Located under the direction indicator control, this control has four positions and can be operated only when the ignition is switched on.

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Travel control pedal

Template Name: OM_1_col Template Date: 1994_04_29

Lighting control

CONTROLS/INSTRUMENTS/ACCESSORIES

Attachment control lever

Bucket locking or 4-in-1 bucket clam control lever

Template Name: OM_1_col Template Date: 1994_04_29

4 2

1

1

0

0

2

3

5

PH03430A

Located on the right of the seat, this lever has six positions.

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Lever in position (0): Neutral.

Lever in position (1): The attachment lowers.

Lever in position (2): The attachment is floating (the bucket follows the contours of the ground).

Lever in position (3): The attachment rises.

Lever in position (4): The bucket tilts forward (dumping).

Lever in position (5): The bucket tilts to the rear (filling).

Only position (2) has a self-maintaining function. The other positions automatically return to the neutral position (0).

NOTE : The movement speed of the attachment depends on the angle to which the control lever is tilted.

PH03430A

Located on the right of the seat, this lever has three positions.

Lever in position (0): Neutral.

CD97E031

Lever in position (1): Bucket locking or 4-in-1 bucket clam opening.

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CONTROLS/INSTRUMENTS/ACCESSORIES

Parking brake lever CDS97E030

Lever in position (2): Bucket unlocking or 4-in1 bucket clam closing.

Attachment control locking knob CD97E037

The parking brake lever is located on the left of the seat. When the lever is raised, the wheels are braked. When the lever is lowered, the wheels are freed.

To lower the lever, press the push-button located on the end of the lever.

CD97E029

Located under the attachment controls, this knob has two positions:

NOTE : If the lever is raised when the direction of travel selector is not in the neutral position (N), the audible warning device will sound and the parking brake warning lamp will light up on the control panel.

Knob pulled forward: the attachment control levers are unlocked.

Knob pushed backward: the attachment control levers are locked.

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NOTE : When this lever is released, it automatically returns to position (0) (neutral).

Template Name: OM_1_col Template Date: 1994_04_29

WARNING : To enter or leave the operator’s compartment, it is mandatory for the knob to be pushed backward.

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NOTE : The knob can be locked in the forward position (controls unlocked) by turning it half a turn.

CONTROLS/INSTRUMENTS/ACCESSORIES NOTE : In cold weather, add anti-freeze to the water in the windshield washers.

Engine hood opening control handle Template Name: OM_1_col Template Date: 1994_04_29

IMPORTANT : Never operate the windshield washers when the reservoir is empty. This could cause damage to the electric pump.

Brake fluid reservoir

CD97E037

Located on the left of the seat, this handle is used to unlatch the engine hood.

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IMPORTANT : Make sure that the rear window is closed and locked before opening the engine hood.

CD97E033

Located on the right of the seat underneath the storage compartment, this reservoir has a push-button which is used to check the braking system pressure warning lamp on the control panel. See “Control panel”.

Windshield washer reservoir

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CD97E033

Located on the right of the seat under the storage compartment, this two-litre capacity reservoir is equipped with an electric pump controlled by the front and rear windshield wiper and windshield washer switches.

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CONTROLS/INSTRUMENTS/ACCESSORIES

PH02523

Located on the right of the seat, this compartment is used, among other things, for storing the technical literature and official documents of the machine.

CD97E093

Located on the left of the seat, this compartment is intended to contain the cab ventilation filter.

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Cab light

CD97E012

Located on the right at the top of the cab, this light is controlled by a switch incorporated in the lamp base.

NOTE : To replace the bulb, see “Replacing a bulb” in the “Electrical System” Section.

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Cab ventilation inlet filter compartment

Template Name: OM_1_col Template Date: 1994_04_29

Storage compartment

CONTROLS/INSTRUMENTS/ACCESSORIES

Sun-shield

Inspection light socket (121B Series)

Template Name: OM_1_col Template Date: 1994_04_29

CK97E008

Located at the top of the cab, the sunshield can easily be positioned as required by pulling on its tab.

Raising the sun-shield

PH02509

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Located on the right-hand side of the instrument panel, this socket can be used to connect an inspection light or any other 12 volts electrical appliance.

Rotary light socket

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CD97E028

To raise the sun-shield, press on the lever at the end of the reel.

CD97E027

Located on the left-hand side, outside the cab, this socket is powered by the rotary light switch. See “Control switches”.

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CONTROLS/INSTRUMENTS/ACCESSORIES

Radio (optional)

CD97E028

Template Name: OM_1_col Template Date: 1994_04_29

WARNING : Every year have the fire extinguisher checked by a specialist.

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PH0390

The fire extinguisher is located at the front right-hand side of the operator’s compartment. As soon as you receive the machine, check on how to operate the fire extinguisher. The operating instructions are shown on the fire extinguisher body. Pull the fire extinguisher to remove it from its bracket.

Located on the right at the top of the cab, this compartment is intended for installing a radio (optional).

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Fire extinguisher (optional)

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CONTROLS/INSTRUMENTS/ACCESSORIES

OPERATOR’S SEAT Adjust the seat to the correct position to suit the size of the operator to enable the machine to be operated with maximum efficiency and comfort. The seat is equipped with a seat belt.

Template Name: OM_1_col Template Date: 1994_04_29

3 4

1 2 CD97E026

1. Adjusting the suspension Move the lever to make the suspension harder or softer. Pull the handle and turn it to obtain the desired suspension characteristics.

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2. Adjustment indicator The suspension can be adjusted from 50 kg to 130 kg.

3. Adjusting the fore and aft position Raise the control, slide the seat to the desired position and release the control again.

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4. Adjusting the seatback angle Raise and hold the handle in the raised position until the desired position is obtained, then release the handle.

WARNING : Never operate a working or driving control unless you are correctly seated in the operator’s seat, with the seat belt adjusted and attached before starting the engine. The seat belt will protect you efficiently if you fasten it correctly and always wear it. It should not be too loose. It must not be twisted or caught in the seat.

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CONTROLS/INSTRUMENTS/ACCESSORIES

CK97E010

REAR WINDOW The rear window can be opened for better visibility under certain working conditions or for extra ventilation.

Opening the window 2

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Located on the left and right-hand side of the instrument panel, the fuses which protect the electrical system are located in two fuse boxes. See “Fuses” in the “Electrical System” Section.

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CK97E009

Raise the two handles (1) and slowly push the window. The window is kept in the open position by two gas struts (2).

1

IMPORTANT : Close the window before opening the engine hood.

NOTE : Make sure you close the window at the end of the working day.

PH02715

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Template Name: OM_1_col Template Date: 1994_04_29

Left-hand box

FUSE BOXES Right-hand box

CONTROLS/INSTRUMENTS/ACCESSORIES

HEATING AND VENTILATION blower controls are Air outlets

Template Name: OM_1_col Template Date: 1994_04_29

The heater and located on the left-hand side of the cab.

Heater

2 1 CD97E068

CK97E011

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Place the button (2) in the desired position and set the required blower speed by means of the button (1).

Blower

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CD97E038

2

Air flow can be directed in the desired direction by means of the front and rear air outlets.

1

CK97E011

Turn the button (2) as far as possible anticlockwise and set the required blower speed by means of the button (1).

CD97E025

IMPORTANT : More air will be taken from outside the cab if the air inlet in the cab is closed.

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CONTROLS/INSTRUMENTS/ACCESSORIES

Make sure that the rear view mirrors are correctly adjusted before any travel is undertaken.

IMPORTANT : Do not fold the rear view mirrors completely back against the windshield. This could cause damage to the windshield wiper when in use.

CD97E024

AIR CONDITIONING (Optional)

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The air conditioning controls are located on the right-hand side of the cab.

1 2

CD97E014

Place the button (1) in the required position and set the desired blower speed by means of the button (2).

Air flow can be directed in the desired direction by means of the air outlets

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Template Name: OM_1_col Template Date: 1994_04_29

CD97E084

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REAR VIEW MIRRORS

CONTROLS/INSTRUMENTS/ACCESSORIES

TOWING RING Template Name: OM_1_col Template Date: 1994_04_29

WARNING : Towing is a delicate operation which is always performed at the risk of the user. The manufacturer’s warranty does not cover incidents or accidents which occur during a towing operation.

CD97E023

The towing ring can be used to tow the machine (See “Towing” in the “Operating Instructions” Section) or for towing another machine.

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FUEL TANK NOTE : Clean around the filler cap before re-fuelling.

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NOTE : In cold weather, use fuel corresponding to the ambient temperature, see "Fluids and lubricants" in the "Lubrication/Filters/Fluids" Section.

IMPORTANT : In cold weather, fill the fuel tank at the end of each working day to prevent the formation of condensation.

CD97E039

The fuel tank capacity is 60 litres. The fuel tank filler cap is the screw-on type.

NOTE : The filler cap can be locked using the door key.

WARNING : Never refill the tank when the engine is running. Do not smoke during re-fuelling.

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CONTROLS/INSTRUMENTS/ACCESSORIES

NOTE : Before opening the engine hood, make sure that the rear window is closed.

CD97E037

CD97E022

Raise the hood and tilt it fully back.

Template Name: OM_1_col Template Date: 1994_04_29

WARNING : Make sure the hood is correctly fastened before undertaking any travel.

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Pull forward the unlocking lever located on the left of the seat.

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ENGINE HOOD

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CONTROLS/INSTRUMENTS/ACCESSORIES

FRONT PANEL This panel gives access to the battery.

Template Name: OM_1_col Template Date: 1994_04_29

CD97E021

CD97E020

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To gain access to the panel, raise the attachment, install the attachment locking bar located on the fuel tank and lock the attachment controls.

Remove the two knobs and the front panel.

WARNING : Make sure the panel is securely fastened before undertaking any travel.

WHEEL CHOCK (specific to certain countries)

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This chock is located on the left-hand side of the chassis. Pull the retaining handle and remove the chock from its bracket.

WARNING : Use the wheel chock to immobilize the machine when parking on sloping ground.

MACHINE TOOLS The machine is equipped with the tools necessary for servicing operations.

-

One grease pump One pair of adjustable pliers One flat-ended screwdriver.

One set of open-ended wrenches.

One wheel-nut wrench.

One draining extension pipe.

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OPERATING INSTRUCTIONS

WARNING : Read and assimilate the instructions and warnings shown in this manual before operating the machine.

Before operating the machine, observe the following instructions : - Check the levels (engine oil, hydraulic fluid and coolant solution) and make sure that the various fluids correspond to the conditions of use. See "Operating the machine in cold weather" and "Fluids and lubricants" in the "Lubrication/Filters/ Fluids" Section.

- Carry out the daily maintenance operations. See "Servicing Intervals" Section.

- Walk round the machine, look for any leaks and inspect the hoses. Tighten or replace any items as required. See "Maintenance/Adjustments" Section.

- Before any road or job site work at night, check that the lighting and signalling systems are operating correctly.

- Check the condition and pressure of the tyres. See "Wheels and tyres" in the "Maintenance/Adjustments" Section.

- Clean the steps and access handles. The presence, oil, mud or ice (winter) can cause accidents. Make sure they are always clean.

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- Before travelling on the public highway, lock the attachment and install the safety systems required by regulations. See "Road travel" in the "Job Site And Road Travel" Section.

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BEFORE OPERATING THE MACHINE

- Clean or replace safety decals which are no longer legible. See "Decals" in the "Safety Decals/Hand Signals" Section.

- Make sure that the cab doors are closed correctly.

- Remove anything which might hinder visibility. Clean the windshield windows and rear view mirrors.

- Make sure that no objects or tools are left on the machine or in the operator’s compartment.

- Make sure you know how to evacuate the machine (emergency exit via the righthand door) in case access by the left-hand door is impossible.

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Template Name: OM_1_col Template Date: 1994_04_29

- Make sure that the engine hood and the front panel are closed and correctly fastened.

OPERATING INSTRUCTIONS - Make sure that the right-hand door is not locked.

Template Name: OM_1_col Template Date: 1994_04_29

- Make sure that nobody is under or on the machine. The operator should be the only person on the machine.

- Make sure that nobody is within the working range of the machine.

- Make sure that you know the safety organization of the job site.

OPERATING THE MACHINE WARNING : Check that all the controls and all the safety devices operate correctly in a safe, clear area before beginning work.

When operating the machine the following instructions must be observed : - Start the engine taking into account weather conditions. See "Starting the engine".

- Consult the hourmeter regularly to observe servicing intervals. See "Servicing Intervals" Section.

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- If you use the machine under particularly severe conditions (dusty or corrosive atmosphere, etc.), the Servicing Intervals should be reduced.

- If this machine is new or if the engine has been re-conditioned, See "Running-in period".

- Make sure you know the location of underground pipes or cables before beginning work.

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- Do not work near overhead high-voltage electrical cables without checking beforehand that all necessary measures have been taken to respect the minimum distances : Under 57,000 volts : 3 meters.

Over 57,000 volts : 5 meters.

- On job sites on the public highway, use regulation signals, taking into account the working range of the machine. Local regulations define the number, type and location of reflective strips.

- Make sure that the operator’s seat is correctly adjusted and positioned.

- Never operate any control or driving component unless you are seated correctly in the operator’s seat with the seat belt adjusted and attached correctly.

- Adapt your operating style to the type and conditions of work. See "Operating Instructions" in the "Job Site and Road Operation" Section.

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OPERATING INSTRUCTIONS

- Use all the controls gradually so that the machine works smoothly.

- If the machine has to work in water, see "Operating the machine in water".

- When loading the machine onto the trailer of an articulated vehicle, see "Transporting the machine".

- When towing the machine, see "Towing”.

- Under no circumstance is it permitted to sweep the ground with the attachment to level rubble or to push objects (transverse forces on the attachment).

- Avoid running the engine in an enclosed space. If necessary, ensure good ventilation under all circumstances.

- In case of an operating problem or damage, move the machine to a safe place, immediately lower the attachment to the ground, apply the parking brake, shut down the engine and remove the starter switch key. Locate or report the failure and, if necessary, take measures to prevent the machine being operated. Place a "Do not start up" labelon the instrument panel.

- When stopping the engine take account of weather conditions. See "Stopping the engine".

Template Name: OM_1_col Template Date: 1994_04_29

- When parking the machine, see "Parking the machine".

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- Dust, smoke or fog can reduce visibility and cause an accident. Stop or slow down the machine until normal visibility is restored.

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- Do not allow anyone to stand in the machine working area. Stop all movement until the person has moved away.

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OPERATING INSTRUCTIONS

RUNNING-IN PERIOD Template Name: OM_1_col Template Date: 1994_04_29

A longer life-time, better performance and more economical running can be obtained by paying very close attention to the engine during the first twenty operating hours.

During this period : Keep a close watch on the instrument panel.

Check the oil and coolant solution levels frequently.

Operate the machine at normal speeds during the first eight hours. Do not run the engine too much at stalling speeds (with the wheels turning slowly or stopped and the engine at full speed).

Maintain the engine at the normal operating temperature.

Do not run the engine at idle speed for long periods.

During the running-in period, the following inspections and maintenance operations must be carried out in addition to the operations shown in the Maintenance Programme : TRIM THIS EDGE

AFTER THE FIRST 10 OPERATING HOURS Check the tightness of the wheel nuts and screws. See "Wheels and tyres" in the "Maintenance/Adjustments" Section.

AFTER THE FIRST 20 OPERATING HOURS Drain the oil from the engine. Replace the oil filter. See “Engine” in the “Lubrication/Filters/Fluids” Section.

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AFTER THE FIRST 100 OPERATING HOURS Drain the reduction gears, the front and rear axles and the drop box. See “Axles and reduction gears” in the “Lubrication/Filters/Fluids” Section.

AFTER THE FIRST 500 OPERATING HOURS Replace the hydraulic transmission filter. See “Hydraulic system” in the “Lubrication/Filters/Fluids” Section.

AFTER THE FIRST 1000 OPERATING HOURS Drain the hydraulic system. See “Hydraulic system” in the "Lubrication/Filters/ Fluids" Section.

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OPERATING INSTRUCTIONS

NOTE : If this condition is not observed the audible warning device will sound and it will be impossible to start the engine.

STEP 4

NOTE : If you have to start the engine with a booster battery, see “Connecting a booster battery” in the “Electrical System” Section.

1

STEP 1

4

Adjust the seat and attach the seat belt.

2 3

STEP 2

CD97E037

Check that the parking brake lever is in the raised position.

STEP 3

NOTE : The indicator/warning lamps can be checked for correct operation at this stage of the starting procedure. If necessary, replace any bulbs. See "Replacing a bulb" in the "Electrical System" Section.

CD97E036

Check that the speed selector is in the neutral position (N).

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CK97E002

Turn the starter switch key to the “ON” position. All the indicator/warning lamps and symbols on the monitoring panel and the neutral position indicator lamp, steering pressure and the indicator lamp showing the position of the speed selector on the control panel should light up. After a few seconds, only the engine oil pressure (1), battery (4), steering pressure (2), pre-heat indicator lamp (3), speed selector neutral position and the indicator lamp showing the position of the speed selector should remain on.

Template Name: OM_1_col Template Date: 1994_04_29

NOTE : After the machine has not been operated for an extended period, see "Starting up after storage" in the "Storing" Section.

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STARTING THE ENGINE

OPERATING INSTRUCTIONS IMPORTANT : Do not operate the starter for more than 30 seconds at a time. Do not operate the starter when the engine is running.

STEP 5

Template Name: OM_1_col Template Date: 1994_04_29

STEP 6 When the engine is running check the indicators and indicator lamps to make sure that all systems are operating correctly.

2 1

STEP 7 CK97E002

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Once the pre-heat indicator lamp (1) has gone out, operate the starter motor by turning the key (2) to the starting position.

Release the key when the engine starts turning. If the engine stops, wait about one minute before starting the operation again.

Run the engine at half speed until it has reached normal running temperature.

NOTE : Do not run the engine at idle for too long, since this may cause the formation of deposits in the oil. Whenever conditions of use and safety allow it, run the engine at maximum speed.

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OPERATING INSTRUCTIONS

SHUTTING DOWN THE ENGINE STEP 3 Allow the engine to run at idle speed for about one minute.

IMPORTANT : In cold weather, run the engine at low idle speed for three to five minutes to reduce the engine temperature before turning off completely.

STEP 4

CD97E036

Place the speed selector in the neutral position (N).

CK97E002

Turn the starter switch key to the "Off" position.

IMPORTANT : If the engine is to be stopped for a long period, see "Parking the machine".

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STEP 2

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STEP 1

CD97E037

NOTE : The audible warning device will sound if the parking brake lever is raised while the speed selector is not in the neutral position (N).

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Template Name: OM_1_col Template Date: 1994_04_29

Raise the parking brake lever.

OPERATING INSTRUCTIONS

OPERATING THE MACHINE IN COLD WEATHER Observe the following recommendations :

Template Name: OM_1_col Template Date: 1994_04_29

Battery

Hydraulic fluid

It must be fully charged.

It must have a viscosity corresponding to the ambient temperature. See "Fluids and lubricants" in the "Lubrication/Filters/Fluids" Section.

Fuel a) To prevent the formation of condensation and the introduction of water into the fuel system, fill the fuel tank after each working day and drain water from the bottom of the fuel tank after each working day.

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b) To prevent the formation of crystals (-2°C), use a fuel corresponding to the ambient temperature or mix a protective substance with your fuel.

See "Fluids and lubricants" in the "Lubrication/Filters/Fluids" Section.

Coolant solution It must have a specification corresponding to the ambient temperature. It must contain a minimum of 50% of ethylene glycol solution. See "Fluids and lubricants" in the "Lubrication/Filters/Fluids" Section.

Engine oil

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The engine oil must have a viscosity corresponding to the ambient temperature. See "Fluids and lubricants" in the "Lubrication/Filters/Fluids" Section.

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OPERATING INSTRUCTIONS

OPERATING THE MACHINE IN HOT WEATHER 1. Maintain the correct level of coolant solution in the radiator.

2. Check the state of the radiator cap before starting the engine. Replace the cap if necessary.

3. Carefully clean the radiator and the engine.

4. Check the condition of the drive belt.

5. Use lubricants with the specified degree of viscosity.

6. Use a suitable coolant solution (a mixture of ethylene glycol and water to the required concentration). See "Fluids and lubricants" in the "Lubrication/Filters/ Fluids" Section.

Template Name: OM_1_col Template Date: 1994_04_29

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7. Operate the air filter dust ejector more frequently when the machine is used in particularly dusty areas.

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Observe the following recommendations :

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OPERATING INSTRUCTIONS

TRANSPORTING THE MACHINE On a railway wagon Template Name: OM_1_col Template Date: 1994_04_29

Since railway transport is subject to special regulations, please consult an approved organization.

On a trailer WARNING : This machine can slip and fall from a trailer or ramp and cause serious physical injury. Make sure that the trailer and the ramp are both clean. The machine must be in line with the trailer before being loaded.

Make sure you know the safety rules and regulations before transporting this machine. Make sure that the trailer and the machine are equipped with the correct safety equipment.

Loading TRIM THIS EDGE

STEP 2

STEP 1

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CD95M248

CD97E027

Place a chock behind the wheels of the trailer. Install the trailer side extensions (if equipped).

Remove the rotary light and store it in the cab.

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OPERATING INSTRUCTIONS

CD97E040

Install the articulation locking pin and its retaining pin.

STEP 4

STEP 7

STEP 6

CD97E029

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Stop the engine and remove the starter switch key.

CD97E041

Lower the bucket to the floor of the trailer and push the attachment control locking handle backward.

Make sure that the rear window, the doors, the engine hood and the front panel are closed and correctly locked.

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Template Name: OM_1_col Template Date: 1994_04_29

CD97E036

Raise the bucket twenty centimetres above the trailer ramps. Load the machine carefully onto the trailer (select forward job site travel), then place the speed selector in the neutral position (N) and raise the parking brake.

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STEP 5

STEP 3

OPERATING INSTRUCTIONS

Unloading

STEP 8

STEP 1

Template Name: OM_1_col Template Date: 1994_04_29

Remove the chocks and the retaining chains.

STEP 2 Remove the articulation locking pin.

STEP 3 Start the engine.

STEP 4

CD97E041

Turn the rear view mirrors inwards.

Pull the attachment control locking handle forward.

STEP 9 Use chocks and chains to immobilize the machine and the attachment on the trailer.

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STEP 10

STEP 5 Raise the attachment so that it is a few centimetres above the floor oft the trailer.

STEP 6

Measure the distance between the ground and the highest point of the machine. You must know the total height.

Lower the parking brake lever.

STEP 7

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Place the speed selector in the job site reverse travel position and press the travel pedal to adjust the travel speed.

STEP 8 Reverse slowly while raising the attachment so as to keep it a few centimetres above the floor of the trailer.

STEP 9 Return the rear view mirrors to their correct position.

STEP 10 Place the rotary light on the cab roof.

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OPERATING INSTRUCTIONS

WARNING : Towing is a delicate operation which is always performed at the risk of the user. The manufacturer’s guarantee does not apply to incidents or accidents occurring during towing.

Another machine WARNING : It is mandatory for towing to be carried out using a towing bar of suitable dimensions for the machine being towed.

IMPORTANT : When towing any machine, you must conform to current regulations.

The machine itself

WARNING : It is mandatory for towing to be carried out using a towing bar.

IMPORTANT : Before towing, install the attachment locking systems. See "Road travel" in the "Job Site And Road Travel" Section.

The universal joints must be uncoupled before towing.

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WARNING : The machine must be towed on flat, level ground, very slowly, over a short distance and only if it is really necessary.

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TOWING

Tools required

STEP 1

STEP 2

Install the chocks under the machine’s wheels.

Before uncoupling the components, mark them for identification.

NOTE : Identification marks will facilitate their installation.

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Template Name: OM_1_col Template Date: 1994_04_29

- One 19 mm hexagonal wrench - One towing bar

OPERATING INSTRUCTIONS STEP 6

STEP 3

Template Name: OM_1_col Template Date: 1994_04_29

CD97E066

CK97E004

Remove the universal joint fastenings at the front axle. Support the transmission shaft by means of a sling.

Switch on the rotary light control.

STEP 7

STEP 4 TRIM THIS EDGE

Repeat Steps 2 and 3 for the rear universal joint.

STEP 5

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CD97E032

Switch on the hazard warning light control.

IMPORTANT : Tow the machine at a maximum speed of 1 kph and over a maximum distance of 1 to 2 km.

CD97E023

Install and fasten a towing bar to the towing eye at the rear of the machine and remove the wheel chocks.

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OPERATING INSTRUCTIONS

1.

Make sure that the bed of the stream or stretch of water can support the weight of the machine.

2.

The maximum water level is at the mid-point of the wheels.

IMPORTANT : Never work in a stretch of water if the level is higher than the midpoint of the wheels.

Before immersing the machine, pump plenty of new grease into the machine’s attachment linkages.

IMPORTANT : Never work in fast-flowing water.

STEP 1

STEP 5

Park the machine on a flat, level surface away from any soft ground, excavations or poorly shored cavity.

Stop the engine and remove the starter switch key.

STEP 2

STEP 6

Lower the bucket to the ground.

Push the attachment control locking knob backward.

STEP 3

STEP 7

Place the speed selector in the neutral position (N).

Lock the operator’s compartment doors.

STEP 4 Immobilize the machine by means of the parking brake.

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PARKING THE MACHINE

STEP 8 If the machine is parked outdoors, cover the exhaust pipe so as to protect the engine against damp.

WARNING : Never jump down from the machine. To dismount from the operator’s compartment always face the machine and use the steps and access handles.

WARNING : Make sure that no part of the machine is protruding onto the public highway. If this cannot be avoided, install signs in conformity with regulations.

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Template Name: OM_1_col Template Date: 1994_04_29

3.

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OPERATING THE MACHINE IN WATER

JOB SITE AND ROAD OPERATION

INSTRUCTIONS FOR USE Template Name: OM_1_col Template Date: 1994_04_29

WARNING : Observe the instructions for use given in this chapter. Any other practice without the prior approval of the manufacturer is considered as being forbidden.

Road operation IMPORTANT : Road speed is subject to restrictions in certain countries. It is the operator’s responsibility to limit his speed accordingly.

- Before any road travel, lock the attachment and install the safety systems required by regulations. The machine must be within the maximum dimensions permitted on the road in accordance with local road traffic regulations.

- Check that the lighting and signalling systems operate correctly.

- Check that the brakes and steering operate correctly.

- Check the condition and pressure of the tyres.

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- Never alight from the operator’s compartment leaving the engine running.

- All travel must take place with the speed selector in forward travel and with the cab doors closed.

Job site operation

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- Be vigilant, be aware of places where other persons are working close to your working area. Keep other persons away from the machine. Serious physical injury can result if these instructions are not observed.

- Make sure you know the location of underground pipes or cables before beginning work. Electrical cables, gas pipes, water pipes or other underground installations can cause serious physical injury.

- Adapt your driving style to suit the conditions of work (sloping ground or rough ground), the state of the road and weather conditions.

- When travelling at right angles to a slope the bucket must be kept level with the ground.

- When travelling in the same direction as the slope, drive onto the slope in slow speed (job site speed). Never drive down a slope with the speed selector in the neutral position.

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JOB SITE AND ROAD OPERATION

WARNING : Always fasten your seat belt before travelling on the road.

STEP 3

Before travelling on the road, it is essent and install the safety systems required by

PH02205

Install the bucket tooth-cover.

NOTE : Install the registration plate, the warning triangle and the reflectors (special for certain countries).

PH02917

Install the bucket locking bar.

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STEP 1

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ROAD TRAVEL

CD97E041 CD97E029

Push the knob backward so as to lock the attachment controls.

Adjust the rear view mirrors correctly.

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Template Name: OM_1_col Template Date: 1994_04_29

STEP 4

STEP 2

JOB SITE AND ROAD OPERATION STEP 5

STEP 7

Start the engine.

Press the brake pedal fully down. Lower the parking brake lever.

Template Name: OM_1_col Template Date: 1994_04_29

STEP 6

STEP 8 Place the speed selector in position (3) (forward road travel).

STEP 9 Release the brake pedal and control the travel speed by means of the travel pedal.

NOTE : Maximum travel speed is 24 kph; 20 kph (Special for Germany).

CK97E004

Switch on the rotary light control.

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WARNING : During travel, check the indicator lamps frequently.

WARNING : Before travelling, check that the lighting and signalling systems are working correctly.

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JOB SITE AND ROAD OPERATION

JOB SITE TRAVEL Release the brake pedal and control the travel speed by means of the travel pedal.

IMPORTANT : Wait for the machine to stop completely before changing the direction of travel.

Start the engine.

STEP 2 Press the brake pedal fully down. Lower the parking brake lever.

NOTE : Travel speed is 9 kph.

STEP 3 Place the speed selector in position (2) (job site forward travel).

WARNING : Always fasten your seat belt before starting the engine.

WARNING : Always be vigilant. Do not allow any unauthorized personnel in the working area. Make sure you always know the exact position of every person who has to be within the working area.

WARNING : Operate the machine with the bucket as low as possible.

This low position will give the machine improved stability and will provide you with better visibility. If the bucket is full and you are moving the machine over rough ground or over slippery surfaces, drive more slowly. If you do not follow these instructions, you may lose control of the machine and cause it to turn over.

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LOADER OPERATING INSTRUCTIONS

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STEP 1

STEP 4

Template Name: OM_1_col Template Date: 1994_04_29

NOTE : After road travel, remove all the road safety devices before carrying out any job site travel.

JOB SITE AND ROAD OPERATION

Flat ground

Bucket position indicator

Template Name: OM_1_col Template Date: 1994_04_29

Adjust the position of the bucket so that the front of the bucket is lower than the rear. The bucket teeth will help you to dig in this type of work.

Move the machine into the area to be dug with the speed selector in low speed and the engine at full speed. Lower the bucket to the ground. When the bucket has reached the correct depth, bring the bucket up to the horizontal position and continue moving forward.

When the bucket is full, tilt the bucket backward. You will waste time if you push the material in front of the bucket.

Heap of rubble

CD97E083

This indicator has two markers located on the bucket cylinder. When the markers are opposite each other the bucket is horizontal and off the ground.

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Check that the bottom of the bucket is really horizontal. Set the speed selector in low speed and the engine at full speed.

Drive the machine into the heap of material. When the travel speed of the machine starts to decrease, raise the attachment and tilt the bucket backward.

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Loading trucks Be very cautious when you are loading trucks. Raise the load and move the machine towards the side of the truck.

Use the brake pedal to slow down the machine. While you are moving towards the truck, use the attachment height control to position the bucket at the correct height. After dumping the load, position the bucket ready for the next cycle.

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Template Name: OM_1_col Template Date: 1994_04_29

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SERVICING INTERVALS

SERVICING INSTRUCTIONS Template Name: OM_1_col Template Date: 1994_04_29

Observe the servicing intervals by the checking the hourmeter every day. Before starting any servicing procedure, park the machine on flat, hard ground, away from obstacles, with the bucket on the ground. Unless otherwise specified, all servicing operations must be conducted with the engine shut down and the starter switch key removed. It is preferable to wait for all circuits to cool down before starting work.

Clean the grease fittings before lubrication. Clean around plugs and filler holes before adding oil. No dust or dirt must enter the components or the circuits.

WARNING : There is a risk of serious injury if maintenance or repairs are not performed correctly. If you do not understand the maintenance procedures, consult your CASE Dealer.

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WARNING : If the attachment is in raised position or the machine moves when there is no operator, serious injury can result. Before carrying out any servicing operator on this machine, proceed as follows : 1. Park the machine on flat, level, stable ground.

2. Lower the attachment until it is resting on the ground.

3. Shut down the engine and remove the starter switch key.

4. Raise the parking brake lever.

5. Lock the attachment controls.

6. Lock the wheels to prevent all machine movement.

If the servicing operations require the attachment to be in the raised position, install the attachment locking system.

WARNING : Never leave the operator’s compartment when the engine is running.

Before starting any servicing operation on the machine, place a “Do not start up” label on the instrument panel.

Any modification to this machine without prior authorization could cause serious injury. Do not make any modifications without authorization. Consult your CASE Dealer.

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SERVICING INTERVALS

IMPORTANT : Observe the Servicing Intervals for all the machine’s filters. The life of the engine depends on clean filters.

IMPORTANT : Do not drain used oil into the ground or pour it down a drain. It must be stored and removed by a company responsible for recycling or disposal of oil.

HOURMETER The hourmeter enables servicing operations to be scheduled. It works in the same way as a clock when the engine is running.

Be sure to carry out all the servicing operations properly, as defined in this manual.

Template Name: OM_1_col Template Date: 1994_04_29

CK97E002

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Servicing Intervals are properly calculated to guarantee safe and efficient machine operation.

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IMPORTANT : If you are using the machine under particularly severe conditions (dusty or corrosive environment, etc.), reduce the intervals between services.

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SERVICING INTERVALS

SERVICING INTERVALS Template Name: OM_1_col Template Date: 1994_04_29

N 0

INTERVALS IN HOURS

0 F

P A G E 96 96 96

P O I N T S 4 2

SERVICE POINTS 4-in-1 bucket cylinders (optional) 4-in-1 bucket linkage (optional)

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96

Quick coupler linkage on arm and connecting rod Bucket locking cylinder

2

101 98 106

Engine oil level Coolant solution level Fuel pre-filter bleed

1 1 1

109 113 127

Dust ejector Hydraulic reservoir level Radiator and oil cooler

1 1 1

128 92 92 93 93 93 93 97 97 97 97 94

Fan/alternator drive belt Transmission/front axle universal joint Transmission/rear axle universal joint Rear axle pivot Central pivot Articulation cylinder bottom Articulation cylinder top Connecting rod yoke linkage Bucket cylinders Arm linkage on chassis Attachment cylinders Accelerator pedal

1 2 2 1 1 1 1 2 2 2 4 1

94 95 95

Attachment control lever Bucket locking control lever Option control lever (if equipped)

1 1 1

125 148 113 117 117 125

Tyre pressures Battery electrolyte level Hydraulic oil filter Axle reduction gear oil levels Axle oil levels Wheel nut tightening (NOTE 4)

4 1 1 4 2 16

C L E A N

R E P L A C E

C H E C K

3

10 10 10 10 10 10

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G R E A S E 10 10

10 10 10 50 50 50 50 50 50 50 50 50 50 100 100 100 100 100 100 200 200 200 200

D R A I N

SERVICING INTERVALS N 0 0 F

112 93 106

Cab ventilation inlet filter Engine hood hinges Fuel filter

1 2 1

106 128 106

Fuel pre-filter Alternator/fan drive belt tension Fuel pump

1 1 1

117 117 124

Axle reduction gears (NOTE 3) Axles (NOTE 3) Brake wear limits

4 2 1

131 151 151 103 123 113 131 152 53

Machine inspection Alternator Starter motor Cooling system Brake system Hydraulic system (NOTE 2) Valve rocker clearances Injectors Fire extinguisher

1 1 1 1 1 1 8 4 1

109 137

Air filter element Cylinders

1 3

C H E C K

G R E A S E

D R A I N 250

250 250 250 250 250 400 400 400 400 1000 1000 1000 1000 1000

1000 1000 1000 2000 2000 2000 2000

2000 (1) (2)

(2) (3)

(1) Have checked once a year by a specialist.

(2) Clean or replace when the warning lamp lights up on the instrument panel or replace once a year or after cleaning 6 times.

(3) Check for leaks.

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Template Name: OM_1_col Template Date: 1994_04_29

SERVICE POINTS Engine sump oil (NOTE 1) Engine oil filter (NOTE 1) Cooling system hose clamp tightening Brake fluid level Radiator and oil cooler

C L E A N

R E P L A C E

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P A G E 101 101 103 123 127

P O I N T S 1 1 1 1

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INTERVALS IN HOURS

SERVICING INTERVALS NOTE 1 : Drain and replace after the first 20 hours during the running-in period.

NOTE 2 : Drain after the first 1000 hours during the running-in period.

Template Name: OM_1_col Template Date: 1994_04_29

NOTE 3 : Drain after the first 100 hours during the running-in period.

NOTE 4 : Check after the first 10 hours during the running-in period.

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Template Name: OM_1_col Template Date: 1994_04_29

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LUBRICATION/FILTERS/FLUIDS

FLUIDS AND LUBRICANTS Fluids and lubricants must have the correct properties for each application.

Template Name: OM_1_col Template Date: 1994_04_29

WARNING : It is essential that the instructions for use of the various fluids and lubricants are observed.

Hydraulic fluid Use a fluid corresponding to the standard and the specification: FORD M-2C-86B ALLISON C3.

Engine oil Use an oil corresponding to the standard and specification: API CD/SE or MIL-L-2104D TRIM THIS EDGE

Oil for axle with limited slip differential

Oil for drop box and reduction gears Use an oil corresponding to the standard and specification: FORD M-2C-86B ALLISON C3.

Grease Use a grease corresponding to the standard and specification: EP LITIO NGLI 2.

Brake fluid

Use an oil corresponding to the standard and specification: API GL 5 or ZF TE-ML 05

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Oil for axle with standard differential Use an oil corresponding to the standard and specification: FORD M-2C-86B ALLISON C3

Use a brake fluid corresponding to the standard and specification DOT 4 SAE J1703F. It should not be mixed with mineral or silicone based oils.

NOTE : Never add any performance or other additive product to the engine oil sump. Engine oil change intervals are shown in this manual in accordance with tests performed on CASE lubricants.

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LUBRICATION/FILTERS/FLUIDS

B IO36LO

(A) FAHRENHEIT TEMPERATURE

(B) CENTIGRADE TEMPERATURE

Fuel

IMPORTANT : In cold weather, fill the fuel tank after each day’s work, to prevent the formation of condensation.

Use No. 2 type fuel. The use of other fuels may cause loss of engine power and excessive fuel consumption.

In cold weather, it is temporarily permitted to mix fuels No. 1 and No. 2. Consult your fuel supplier.

If the temperature falls below the fuel cloud point (point at which wax appears), wax crystals in the fuel will cause a loss of engine power or make it impossible to start the engine.

Fuel Storage Prolonged fuel storage causes foreign bodies or condensation water to accumulate in the storage tank. Many engine failures are caused by the presence of water in fuel.

The storage tank should be placed outdoors and the fuel should be kept at as low a temperature as possible. Condensation water should be drained off at regular intervals.

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Template Name: OM_1_col Template Date: 1994_04_29

The fuel to be used must be in conformity with the D975 standard of the American Society for Testing and Materials (ASTM).

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A

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Oil viscosity/oil operating range

LUBRICATION/FILTERS/FLUIDS

Anti-freeze/anti-corrosion Template Name: OM_1_col Template Date: 1994_04_29

Use anti-freeze in all seasons to protect the cooling system from corrosion and all risk of freezing.

For environments with a temperature above -36°C, use a mixture with 50% ethylene glycol based anti-freeze.

For environments with a temperature below -36°C, a mixture of 40% water and 60% anti-freeze is recommended.

ENVIRONMENT Before carrying out any servicing operation on this machine and before disposing of used fluids or lubricants, always think of the environment. Never throw oils or fluids on the ground and never place them in leaky receptacles.

Consult a local recycling or ecological centre or a CASE Dealer to obtain information on the correct method of disposing of these materials.

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PLASTIC AND RESIN PARTS When cleaning plastic windows, the console, the instrument panel, the indicators, etc., avoid using petrol, paraffin, paint solvents, etc.. Use only water, soap and a soft cloth.

The use of petrol, paraffin, paint solvents, etc.. will cause discoloration, cracking or deformation of such parts.

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LUBRICATION/FILTERS/FLUIDS

COOLING SYSTEM System capacity ..........................................................................................12 litres FUEL SYSTEM Tank capacity ..............................................................................................60 litres

BRAKING SYSTEM Fluid type..................................................................................DOT 4 SAE J1703F System capacity .........................................................................................1.1 litres AXLE WITH STANDARD DIFFERENTIAL Type of oil............................................................... FORD M-2C-86B ALLISON C3 Total capacity (each axle).........................................................................10.5 litres Differential capacity ..................................................................................3.85 litres AXLE WITH LIMITED SLIP DIFFERENTIAL (Marked AB...)

Type of oil....................................................................... API GL 5 or ZF TE-ML 05 Total capacity (each axle).........................................................................10.5 litres Differential capacity (each differential) .....................................................3.85 litres REDUCTION GEARS Type of oil............................................................... FORD M-2C-86B ALLISON C3 Capacity (each reduction gear) ..................................................................2.2 litres

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HYDRAULIC SYSTEM Type of fluid............................................................ FORD M-2C-86B ALLISON C3 Total system capacity ..................................................................................70 litres Tank capacity ..............................................................................................50 litres

Template Name: OM_1_col Template Date: 1994_04_29

ENGINE Type of oil.........................................................................API CD/SE MIL-L-2104D Capacity (with the filter change).................................................................5.5 litres

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FLUID AND LUBRICANT CAPACITIES AND SPECIFICATIONS

LUBRICATION/FILTERS/FLUIDS

GREASE POINTS Machine Template Name: OM_1_col Template Date: 1994_04_29

Tools required - Grease pump (supplied with the machine) Type of grease ..............................................................See “Fluids and lubricants" NOTE : The figures shown in brackets show the number of grease points.

3 5

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6 1 7

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2

1

4 CD97E097

Every 50 hours

Every 50 hours

1

2

CD97E066

CD97E065

Universal joint between drop box and front axle........................................ (2)

Universal joint between drop box and rear axle............................... (2)

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LUBRICATION/FILTERS/FLUIDS Every 50 hours

Every 50 hours

6

PH03026

CD97E061

Rear axle pivot ................................(1)

Articulation cylinder top ...................(1)

Every 50 hours

Every 400 hours

7 TRIM THIS EDGE

4

CD97E063

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3

CD97E064

Central pivot ....................................(2)

Engine hood hinges.............................. (2)

5

CD97E062

Articulation cylinder bottom .............(1)

93

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Template Name: OM_1_col Template Date: 1994_04_29

Every 50 hours

LUBRICATION/FILTERS/FLUIDS

Cab Tools required Template Name: OM_1_col Template Date: 1994_04_29

- Grease pump (supplied with the machine) Type of grease ..............................................................See “Fluids and lubricants" NOTE : The figures shown in brackets show the number of grease points.

1

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2

4

3

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CD97E082

Every 100 hours

Every 100 hours

1

2

CK97E005

CD97E081

Accelerator pedal ............................ (1)

Attachment control lever ................. (1)

94

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LUBRICATION/FILTERS/FLUIDS Every 100 hours

Every 100 hours

4

CD97E081

CD97E081

Option control lever (if equipped) ................................(1)

Template Name: OM_1_col Template Date: 1994_04_29

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Bucket locking or clam control lever for 4-in1 bucket (optional) ............................ (1)

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3

95

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LUBRICATION/FILTERS/FLUIDS

Attachment Tools required Template Name: OM_1_col Template Date: 1994_04_29

- Grease pump (supplied with the machine) Type of grease ..............................................................See “Fluids and lubricants" NOTE : The figures shown in brackets show the number of grease points.

3 5 4

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1 2

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CD97E041

Every 10 hours

Every 10 hours

1

2

CD97E080

CD97E079

4-in-1 bucket cylinders (optional)..................................... (4) 4-in-1 bucket linkage (optional) ....... (2)

Quick coupler linkage on arm...............(2) Quick coupler linkage on connecting rod..................................(1) Bucket locking cylinder .........................(2)

96

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LUBRICATION/FILTERS/FLUIDS Every 50 hours

Every 50 hours

5

CD97E077

CD97E083

Attachment cylinders .......................(4) Arm linkage on chassis ...................(2)

Bucket cylinder................................(2)

Every 50 hours

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4

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3

97

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Template Name: OM_1_col Template Date: 1994_04_29

CD97E078

Connecting rod linkage on yoke ......(1) Yoke linkage ....................................(1)

LUBRICATION/FILTERS/FLUIDS

LEVELS NOTE : The figures in brackets show the number of level points.

Template Name: OM_1_col Template Date: 1994_04_29

2

8 1

3 TRIM THIS EDGE

4

6

7

5

CD97E096

Every 10 hours

Every 10 hours

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1

2

CD97E060

CD97E059

Engine oil ........................................ (1) API CD/SE OR MIL-L-2104D

Radiator .......................................... (1) ETHYLENE-GLYCOL AND WATER

98

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LUBRICATION/FILTERS/FLUIDS Every 200 hours

Every 10 hours

5

CD97E007

PH03026

Hydraulic reservoir ..........................(1) FORD M-2C-86B ALLISON C3 Every 200 hours

Rear axle.........................................(1) (Depending on type, see “Fluid and lubricant capacities and specifications).

Every 200 hours TRIM THIS EDGE

4 6

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3

CD97E067 PH01533

Reduction gears ..............................(4) FORD M-2C-86B ALLISON C3

99

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Template Name: OM_1_col Template Date: 1994_04_29

Front drive axle ...............................(1) (Depending on type, see “Fluid and lubricant capacities and specifications).

LUBRICATION/FILTERS/FLUIDS Every 250 hours

Every 200 hours

7

8

Template Name: OM_1_col Template Date: 1994_04_29

CD97E058

Drop box ......................................... (1) FORD M-2C-86B ALLISON C3

CD97E033

Brake fluid ....................................... (1) DOT 4 SAE J1703F

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LUBRICATION/FILTERS/FLUIDS

ENGINE Oil level check ............................................................ Every 10 hours or every day Oil change ..................................................................................... Every 250 hours (after the first 10 hours during the running-in period) Oil filter replacement ..................................................................... Every 250 hours (after the first 10 hours during the running-in period) Oil capacity...................................................................................................... 5.5 L Type of oil..................................................................... See “Fluids and lubricants" STEP 3

STEP 1

STEP 2

PH0441

The level should be between the “Min” and “Max” marks. If necessary, top up via the filling orifice.

CD97E060

After the engine has been stopped for 15 minutes, remove the dipstick, clean it with a clean cloth, replace it in the guide tube as far as it will go and then remove it again.

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Park the machine on flat, level ground.

Shut down the engine and remove the starter switch key.

Oil change and oil filter replacement Tools required - Draining extension (supplied with the machine).

- One filter wrench - One receptacle NOTE : Drain the engine when it is still hot. The oil will flow more easily.

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Template Name: OM_1_col Template Date: 1994_04_29

Oil level check

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Service specifications

LUBRICATION/FILTERS/FLUIDS

Template Name: OM_1_col Template Date: 1994_04_29

STEP 1

STEP 5

Park the machine on flat, level ground.

Shut down the engine and remove the starter switch key.

Install the new filter. Turn the filter until the seal is in contact with the filter head and then tighten it half a turn more by hand.

STEP 2

IMPORTANT : Do not use the filter wrench to install the filter. Excess tightening can damage the seal and the filter.

STEP 6 Remove the draining extension. Install the protective plug.

STEP 7

CD97E060

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Place the receptacle under the drain plug.

Remove the protective plug from the drain valve. Screw on the draining extension and allow the oil to flow out.

STEP 3 CD97E057

Fill the engine with new oil (5.5. litres).

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STEP 8 Run the engine for a few minutes. Check for leaks and check the level again.

NOTE : Always wait fifteen minutes to allow the oil to return to the engine sump before checking the oil level.

CD97E060

Clean around the filter and remove it, using the filter wrench.

STEP 4 Apply clean oil to the new filter seal.

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LUBRICATION/FILTERS/FLUIDS

COOLING SYSTEM Checking the level........................................................................... Every 10 hours Checking the tightness of clamps and hoses ................................ Every 250 hours Oil change ........................................................ Every 2000 hours or every 2 years System capacity ............................................................................................... 12 L WARNING : Boiling coolant solution can escape if the radiator cap is removed when the system is still hot. Before removing the cap, let the system cool down, then turn the cap to the first notch and wait until all pressure is released. Then remove the cap.

WARNING : Check and service the cooling system according to the instructions given in this manual.

Template Name: OM_1_col Template Date: 1994_04_29

Only use coolant solution with ethylene-glycol in the cooling system. Use good quality ethylene-glycol that has a high boiling point, with no additives to prevent leakage. Do not add any non-approved anti-rust additives. Anti-rust additives and ethylene-glycol may mix and mutually destroy each other, which would reduce anti-corrosion protection. They may also form deposits in the cooling system and damage the system and the radiator.

Consult your CASE Dealer for suitable coolant solution.

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Coolant solution

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Service specifications

103

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LUBRICATION/FILTERS/FLUIDS

Level

STEP 1

Template Name: OM_1_col Template Date: 1994_04_29

The level of coolant solution should be checked when the engine is cold.

STEP 1

CD97E059

Remove the radiator cap.

WARNING : Do not remove the cap when the engine is hot. The circuit is still under pressure and you could be scalded.

CD97E059

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With the machine on flat, horizontal ground, before operating the machine (the engine must be cold), remove the radiator cap. The level should be between 2 and 2.5 cm below the filler orifice. If it is not, see "Filling".

STEP 2

STEP 2 Put the radiator cap back on.

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Oil change Tools required - One 10 mm hexagonal wrench - One 14 mm hexagonal wrench.

Place the machine on flat, horizontal ground. Shut down the engine and remove the starter switch key.

CD97E056

Remove the radiator filler cap.

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LUBRICATION/FILTERS/FLUIDS

Run the engine for a few minutes and check the level at the filler orifice again.

The level should be between 2 and 2.5 cm below the filler orifice. Top up if necessary.

STEP 3

CD97E056

Remove the cooler drain plug.

STEP 4

CD97E059

Filling

Put the radiator cap back on.

STEP 1

CD97E059

Fill the radiator to overflowing point.

IMPORTANT : Use the correct coolant solution.

105

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After completely draining the system, replace the radiator and cooler drain plugs.

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STEP 2

Template Name: OM_1_col Template Date: 1994_04_29

STEP 3

LUBRICATION/FILTERS/FLUIDS

FUEL SYSTEM Service specifications Template Name: OM_1_col Template Date: 1994_04_29

Bleeding the fuel pre-filter ............................................................... Every 10 hours Replacing the fuel filter ................................................................. Every 400 hours Cleaning the fuel pre-filter ............................................................. Every 400 hours Cleaning the fuel pump ................................................................. Every 800 hours Rinsing the fuel reservoir ............................................................ Every 1000 hours Fuel tank capacity ............................................................................................ 60 L Type of fuel ...................................................................See “Fluids and lubricants"

Bleeding the fuel pre-filter

STEP 2

STEP 1

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CD97E055

Remove the filter, using a filter wrench.

CD97E053

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Manually unscrew the bleed plug located under the pre-filter and allow the dirty fuel to flow out.

STEP 3

STEP 2

NOTE : Replace the seals if they are damaged.

Retighten the bleed screw.

Replacing the filter Tools required - One filter wrench - One oil or grease can.

STEP 1 Clean around the filter head.

Apply a fine coating of oil or grease on the new filter seals.

STEP 4 Install the new filter. Turn the filter until the seals are in contact with the filter head, then manually tighten the filter half-a-turn more.

IMPORTANT : Do not use the filter wrench to tighten. Excess tightening can damage the seals and the filter.

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Cleaning the pre-filter

STEP 3

Tools required

Install the grille in the pump body and install the cover, using a new seal.

- One 11 mm hexagonal wrench - One 17 mm hexagonal wrench

NOTE : Make sure the cover is correctly installed to prevent any air being drawn into the system.

STEP 4 Bleed the fuel system. See "Bleeding air from the fuel system".

Rinsing the fuel reservoir Tools required - One 27 mm hexagonal wrench

Cleaning the fuel pump

STEP 1 Remove the fuel filler cap.

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CD97E054

Each time the filter is changed, remove the pre-filter, clean it and install it again.

STEP 2

Tools required - One flat-ended screwdriver - One paintbrush

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LUBRICATION/FILTERS/FLUIDS

CD97E091

Place a receptacle of a sufficient capacity under the drain plug and remove the drain plug. Allow the dirty fuel to flow out and replace the drain plug and filler cap.

CD97E053

Remove the cover and its seal and remove the grille from the pump.

STEP 2 Carefully clean the pump body, the grille and the cover.

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Template Name: OM_1_col Template Date: 1994_04_29

STEP 1

LUBRICATION/FILTERS/FLUIDS

Bleeding air from the fuel system

STEP 2

Template Name: OM_1_col Template Date: 1994_04_29

Tools required - One 11 mm hexagonal wrench - One 17 mm hexagonal wrench It is necessary to bleed the fuel system when : - The fuel tank has been completely drained.

- Components of the fuel system have been removed for maintenance or repair.

- The machine has been in storage for quite a long time.

STEP 1

CD97E053

Operate the priming pump until the fuel flows with no air bubbles. Retighten the bleed screw.

STEP 3

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CD97E057 CD97E055

Shut down the engine and remove the starter switch key. Slacken the bleed screw two or three turns.

Slacken the injector unions and operate the starter motor until the fuel flows with no air bubbles. Retighten the connectors.

NOTE : Never operate the starter motor for more than 30 seconds at a time.

Wait 2 minutes before recommencing.

The engine should run smoothly. If air continues entering the system, check that there are no leaks at the unions.

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LUBRICATION/FILTERS/FLUIDS

AIR FILTER Cleaning the dust ejector ........................................... Every 10 hours or every day Servicing the element.................................................................... Clean or replace When the warning lamp on the instrument panel comes on Changing the element ..........................................................................Once a year or after cleaning 6 times IMPORTANT : Carefully observe the air filter service intervals. The life of the engine depends on the cleanliness of the air filter.

IMPORTANT : Reduce the servicing intervals if you use your machine under particularly severe conditions.

Be sure to carry out regular checks on the air filter, intake manifold, gaskets and seals. At the same time, check the intake manifold screws and hose clamps for tightness.

The hoses should be replaced before they are worn.

Check frequently that the air filter restriction warning lamp on the instrument panel is in good working order.

Air filter restriction warning lamp TRIM THIS EDGE

Inspection

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Service specifications

Dust ejector

CD97E050

Operate the valve. Check that it is not clogged.

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Template Name: OM_1_col Template Date: 1994_04_29

CK97E002

If the restriction warning lamp comes on when the engine is running, the air filter element must be checked.

LUBRICATION/FILTERS/FLUIDS

Removing the element

STEP 3

Template Name: OM_1_col Template Date: 1994_04_29

IMPORTANT : The element must be replaced once a year or after being cleaned six times.

STEP 1

CD97E051

Remove the element.

Cleaning the element Tools required CD97E050

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Unscrew the wing-nut (1) and remove the cover (2).

STEP 2

- A compressed air jet IMPORTANT : When using compressed air, take the necessary precautions to protect your face.

STEP 1

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CD97E052

Remove the wing-nut from the element.

PE08311

If the element is dry, blow it with compressed air at very low pressure from inside toward the outside. The air jet should be kept at least 3 cm away from the wall of the element. Cleaning is completed when there is no more dust escaping from the element.

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LUBRICATION/FILTERS/FLUIDS

NOTE : Do not use compressed air if there is oil or soot on the element.

Installing the element STEP 1

STEP 2

CD97E052

Install the element and install and tighten the wing-nut.

STEP 2 TRIM THIS EDGE

PDE0088

If the element is oily, clean it with water and a suitable detergent (consult your CASE Dealer). Instructions for using the detergent are printed on the packaging.

IMPORTANT : The element must be completely dry before being installed. We recommend that you keep a second clean filter element available and install it in the air filter while waiting for the first filter element to dry.

Inspecting the element

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IMPORTANT : Compressed air pressure should not exceed 7 bar.

Tools required - An inspection lamp Check if the element is damaged by placing the inspection lamp inside the element.

IMPORTANT : Replace the element if even the tiniest hole allows light to pass.

111

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Template Name: OM_1_col Template Date: 1994_04_29

CD97E050

Install the cover, correctly orientated, and tighten the wing-nut.

LUBRICATION/FILTERS/FLUIDS STEP 3

Template Name: OM_1_col Template Date: 1994_04_29

Start and run the engine at idle speed and make sure that the restriction warning lamp on the instrument panel is not illuminated.

CK97E002

CAB VENTILATION INLET FILTER Service specifications Cleaning ........................................................................................ Every 250 hours TRIM THIS EDGE

Tools required

STEP 2

- One cross-pattern ended screwdriver.

If the filter is dry, blow compressed air through it. If it is damaged, change it.

STEP 1

IMPORTANT : When using compressed air, take the necessary measures to protect your face.

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STEP 3 Install the filter and the retaining bracket.

CD97E092

Remove the retaining remove the filter.

bracket

and

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LUBRICATION/FILTERS/FLUIDS

HYDRAULIC SYSTEM Checking the hydraulic reservoir fluid level ................ Every 10 hours or every day Replacing the hydraulic fluid filter ................................................. Every 200 hours Draining the circuit ...................................................................... Every 2000 hours (after the first 1000 hours during the running-in period) Tank capacity ................................................................................................... 50 L Total system capacity ....................................................................................... 70 L Type of fluid.................................................................. See “Fluids and lubricants"

Level

CD97E041

Park the machine on flat, horizontal ground, with the bucket parallel to and resting on the ground.

CD97E007

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STEP 3

STEP 1

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Service specifications

Check that the fluid level is between the "Min" and "Max" marks on the gauge. Top up if necessary. See "Filling".

Shut down the engine, remove the starter switch key and wait until the fluid is at ambient temperature.

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Template Name: OM_1_col Template Date: 1994_04_29

STEP 2

LUBRICATION/FILTERS/FLUIDS

Replacing the hydraulic fluid filter

STEP 4

Template Name: OM_1_col Template Date: 1994_04_29

Start the engine, operate the attachment and check for leaks.

Tools required

Replacing the hydraulic fluid

- One 13 mm hexagonal wrench STEP 1

Tools required - One 27 mm hexagonal wrench - One 70 litre receptacle.

Changing the hydraulic fluid consists of systematically draining the fluid from the main components (reservoir, pump, cylinders, control valves and hydraulic motor).

We recommend you consult your CASE Dealer.

CD97E049

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Remove the screws and remove the body.

STEP 2

Oil change Park the machine on flat, level ground.

Shut down the engine and remove the starter switch key.

STEP 1

2

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1

CS97E024

Remove the filter (1) from the filter body and replace it by a new filter. Check the condition of cover seal (2) and change it if necessary.

CD97E007

Remove the reservoir filler cap.

STEP 3 Install the assembly and fasten it with the screws.

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LUBRICATION/FILTERS/FLUIDS

CD97E091

Place the receptacle under the drain plug.

Remove the drain plug and allow the fluid to drain out.

CD97E007

The fluid should be between the "Min" and "Max" marks on the gauge.

STEP 3

STEP 3 TRIM THIS EDGE

Drain the other components by removing the inlet and outlet unions.

STEP 4 Install the reservoir drain plug.

Filling STEP 1 Fill the reservoir with the correct hydraulic fluid.

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STEP 2

STEP 2

CD97E007

Install the filler cap.

Start the engine, carry out some attachment movements, make the machine travel and turn.

STEP 5 Lower the attachment to the ground.

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Template Name: OM_1_col Template Date: 1994_04_29

STEP 4

LUBRICATION/FILTERS/FLUIDS STEP 6

Template Name: OM_1_col Template Date: 1994_04_29

Shut down the engine and remove the starter switch key.

STEP 7

CD97E007

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Check the level. The fluid should be between the "Min" and "Max" marks on the gauge.

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LUBRICATION/FILTERS/FLUIDS

AXLES AND REDUCTION GEARS Checking the axle, reduction gear and drop box oil levels .................................................................................... Every 200 hours Changing the axle oil................................................................... Every 1000 hours (After the first 100 hours during the running-in period) Changing the reduction gear oil .................................................. Every 1000 hours (After the first 100 hours during the running-in period) Front axle oil capacity ................................................................................... 10.5 L Rear axle oil capacity .................................................................................... 10.5 L Oil capacity per reduction gear ....................................................................... 2.2 L Drop box oil capacity ....................................................................................... 1.5 L Type of oil..................................................................... See “Fluids and lubricants"

Reduction gear levels

STEP 3

Tools required TRIM THIS EDGE

- One 12 mm hexagonal key - One 14 mm hexagonal wrench.

STEP 1 Park the machine on flat, level ground.

STEP 2

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Service specifications

2 CD97E041

PH01531

Move the machine until plug (2) is at the top.

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Template Name: OM_1_col Template Date: 1994_04_29

Place the bucket parallel to and resting on the ground.

LUBRICATION/FILTERS/FLUIDS

Draining and filling the reduction gears

STEP 4

Template Name: OM_1_col Template Date: 1994_04_29

2

Tools required - One 12 mm hexagonal key - One 14 mm hexagonal wrench.

- One 3 litre receptacle.

1

STEP 1 Park the machine on flat, level ground.

STEP 2 PH01531

Remove the plug (1), the level should just reach the bottom of the orifice. Top up via the plug orifice (2) if necessary.

STEP 5 TRIM THIS EDGE

2 2 PH01533

Move the machine until the plug (2) is at the top.

1

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STEP 3 PH01531

Install the plugs (1) and (2).

STEP 6 Repeat Steps 2 to 5 for the other reduction gears.

CD97E041

Place the bucket parallel to and resting on the ground.

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LUBRICATION/FILTERS/FLUIDS

2 1 1 2 PH01533

Place the receptacle under the plug (2), remove the plugs (1) and (2) and allow the oil to flow out.

PH01531

Remove the plugs (1) and (2).

STEP 7

Front and rear axle levels

2

Tools required - One 27 mm hexagonal wrench STEP 1

1

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Repeat Steps 2 to 6 for the other reduction gears.

STEP 5

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STEP 6

STEP 4

CD97E041

Place the machine on flat, horizontal ground, with the bucket parallel to and resting on the ground, shut down the engine and remove the starter switch key.

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Template Name: OM_1_col Template Date: 1994_04_29

PH01531

Move the machine until orifice (2) is at the top and fill via this orifice until the oil just reaches the bottom of the orifice.

LUBRICATION/FILTERS/FLUIDS

Changing oil in the front and rear axles

STEP 2

Template Name: OM_1_col Template Date: 1994_04_29

Tools required - One 27 mm hexagonal wrench - One 15 litre receptacle STEP 1

CD97E067

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CD97E041

Place the machine on flat, horizontal ground, with the bucket parallel to and resting on the ground, shut down the engine and remove the starter switch key.

PH03026

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Remove the plugs. The level should just reach the lower edge of the orifice. Top up via these orifices if necessary.

STEP 3 Install the plugs.

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WARNING : The attachment locking system must be installed when servicing operations require the attachment to be raised.

LUBRICATION/FILTERS/FLUIDS

Install the drain plugs (2) and fill via the orifices (1) until the oil just reaches the lower edge of the orifice (1).

1

STEP 4 Install the plugs (1).

Drop box oil level

2

Tools required - One 27 mm hexagonal wrench CD97E067

STEP 1 Park the machine on flat, level ground.

Shut down the engine and remove the starter switch key.

1

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STEP 2

2 PH03026

Place the receptacle under the plugs (2).

Remove the plugs (1) and (2) and allow the oil to flow out.

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STEP 3

STEP 2

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Template Name: OM_1_col Template Date: 1994_04_29

CD97E058

Remove the plug and check that the oil is level with the orifice. Top up via this orifice if necessary.

LUBRICATION/FILTERS/FLUIDS

Changing oil in the drop box

STEP 3

Template Name: OM_1_col Template Date: 1994_04_29

Install the drain plug (2) and fill via the filling orifice (1) until the oil just reaches the lower edge of the orifice.

Tools required - One 27 mm hexagonal wrench - One 5 litre receptacle

STEP 4 Install the plug (1).

STEP 1 Park the machine on flat, level ground.

Shut down the engine and remove the starter switch key.

STEP 2

1

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2 CD97E058

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Place the receptacle under the plug (2), remove the plugs (1) and (2) and allow the oil to flow out.

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LUBRICATION/FILTERS/FLUIDS

BRAKES Checking the brake fluid level ....................................................... Every 250 hours Checking the brake wear limit ..................................................... Every 1000 hours Changing the fluid in the circuit ............................. Every 2000 hours or every year System capacity .............................................................................................. 1.1 L Fluid type...................................................................... See “Fluids and lubricants"

Brake fluid level

Checking the brake fluid level warning lamp

STEP 1

CD97E048

Remove the storage compartment

CD97E048

Remove the storage compartment

STEP 2

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STEP 1

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Service specifications

CD97E033

Check the level of brake fluid in the reservoir. In addition to this check, one can also check the brake fluid level by the warning lamp on the instrument panel. If that warning lamp comes on, top up the brake fluid level. Install the storage compartment.

CD97E033

Shut down the engine and turn the starter switch key to the "ON" position. Press the blue capsule located on the brake fluid reservoir filler cap.

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Template Name: OM_1_col Template Date: 1994_04_29

STEP 2

LUBRICATION/FILTERS/FLUIDS

Checking the disc brake Template Name: OM_1_col Template Date: 1994_04_29

2

1

CK97E002

If the warning lamp does not come on, change the warning lamp bulb. See "Replacing a bulb" in the "Electrical System" Section.

CD97E066

Wear limits: Brake pads (1) ............................. 3 mm Brake disc (2)............................. 10 mm

STEP 3 TRIM THIS EDGE

Install the storage compartment.

Draining and refilling the system Have the system drained and refilled by your CASE Dealer.

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MAINTENANCE/ADJUSTMENTS

WARNING : When checking tyre pressures or during an inflation operation, never stay facing the tyre but always facing the tread surface.

Always use an inflation cage when the wheel is removed from the machine. Keep all other persons away from the area.

WARNING : Never weld near a tyre. It is essential to remove the tyre before any welding operation.

Pressure check ............................................................................. Every 100 hours Checking tightness of wheel nuts.................................................. Every 200 hours (after the first 10 hours during the running-in period)

Tyre pressures Front................................................................................................................ 3 bar Rear ................................................................................................................ 2 bar

Tyre or wheel service

Installing tyres

The servicing of this machine’s tyres and wheels must be carried out only by a qualified mechanic, who will also understand how to inflate the tyres while observing the safety instructions. To prevent any accidents, use a safety device (the tyre inflation cage), suitable tools and observe the procedure. Serious or fatal injury can result from a tyre suddenly flying off a rim (one piece rim) or from the tyre and/or rim components (a wheel consisting of several parts) suddenly flying off a wheel.

When installing a tyre on the wheel, make sure that the tread is orientated as shown in the illustration.

PD0442

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Service specifications

Template Name: OM_1_col Template Date: 1994_04_29

WARNING : A burst tyre can cause serious injury. Check the condition of the tyres regularly and always observe the recommended inflation pressures.

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WHEELS AND TYRES

MAINTENANCE/ADJUSTMENTS

Wheel nut tightening torques

STEP 3

Template Name: OM_1_col Template Date: 1994_04_29

Tools required - A 32 mm hexagonal wrench (supplied with the machine).

Use a lifting device or the attachment to raise the machine until the wheels are no longer in contact with the ground. Shut down the engine and remove the starter switch key.

STEP 4 Place blocks under the axle for the wheel which is to be removed.

STEP 5 Remove the nuts and remove the wheel.

STEP 6 Install a new wheel, observing the orientation of the tread pattern.

PH01533

TRIM THIS EDGE

The torque must be between 55 and 60 daNm.

STEP 7 Install the wheel and tighten the nuts.

STEP 8

Replacing a wheel

Remove the blocks under the axle.

Tools required

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- One 32 mm hexagonal wrench (supplied with the machine).

STEP 9

STEP 1

STEP 10

Park the machine on flat, horizontal, hard ground, free from obstacles, with the bucket parallel to and resting on the ground. Shut down the engine and remove the starter switch key.

Tighten the nuts to a torque of 55 to 60 daNm.

Lower the machine to the ground.

NOTE : Make sure that the new wheel has a sufficient inflation pressure. Reinflate it if necessary.

STEP 2 Loosen the nuts on the wheel to be removed.

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MAINTENANCE/ADJUSTMENTS

RADIATOR AND OIL COOLER Checking for leaks...................................................... Every 10 hours or every day Cleaning ........................................................................................ Every 250 hours

Cleaning

STEP 3

CD97E044

CD97E046

Remove the two knobs.

STEP 2

Clean the radiator and oil cooler.

- Dry dust : use compressed air.

- Mud : use a water jet.

- Oily dust : use perchlorethylene.

IMPORTANT : The use of trichlorethylene is strictly forbidden.

TRIM THIS EDGE

STEP 1

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Service specifications

WARNING : Never leave tools or other objects inside the inlet housing.

CD97E045

Raise the hood and install the strut.

STEP 4 Install the strut and the knobs in their original positions.

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Template Name: OM_1_col Template Date: 1994_04_29

IMPORTANT : When using compressed air, take the necessary precautions to protect your face.

MAINTENANCE/ADJUSTMENTS

ENGINE ALTERNATOR AND FAN BELT Service specifications Template Name: OM_1_col Template Date: 1994_04_29

Visual check ................................................................Every 10 hours or every day Checking belt tension.................................................................... Every 400 hours

Checking belt tension

Adjusting belt tension

STEP 1

Tools required -

One 10 mm hexagonal wrench One 13 mm hexagonal wrench One 15 mm hexagonal wrench One lever

STEP 1

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CD97E041

Park the machine on flat, horizontal ground, with the bucket parallel to and resting on the ground. Shut down the engine and remove the starter switch key.

STEP 2

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CD97E041

Park the machine on flat, horizontal ground, with the bucket parallel to and resting on the ground. Shut down the engine and remove the starter switch key.

PDE0090

Measure the slack in the belt at its longest straight portion.

Maximum slack : 10 mm.

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MAINTENANCE/ADJUSTMENTS

Changing the belt

STEP 2

One 10 mm hexagonal wrench One 13 mm hexagonal wrench One 15 mm hexagonal wrench One 17 mm hexagonal wrench

STEP 1

2 CD97E076

Loosen the screws (1) and (2).

Tighten the belt by means of a lever placed between the engine block and the alternator and retighten the screws (1) and (2).

CD97E041

STEP 4 Check the tension.

Park the machine on flat, horizontal ground, with the bucket parallel to and resting on the ground. Shut down the engine and remove the starter switch key.

STEP 2

CD97E075

Remove the radiator retaining nut.

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STEP 3

Template Name: OM_1_col Template Date: 1994_04_29

-

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Tools required

1

MAINTENANCE/ADJUSTMENTS STEP 6

STEP 3

1 Template Name: OM_1_col Template Date: 1994_04_29

3

2 CD97E076

CD97E076

Loosen the screws (1) and (2) and slide the belt over the pulley (3).

Slide the belt onto the alternator pulley and adjust the belt tension.

STEP 4

STEP 7

Push the radiator slightly to the rear, slide the belt over the fan and remove the belt.

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STEP 5 Pass the new belt over the fan and place it on the water pump pulley.

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CD97E075

Install the radiator retaining nut.

NOTE : When the belt has been changed, check the tension after a few hours of operation.

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MAINTENANCE/ADJUSTMENTS

Service specifications Inspection.................................................................................... Every 2000 hours NOTE : Have them checked by your CASE Dealer.

CHECKING AND CLEANING THE MACHINE Service specifications Inspection and cleaning .............................................................. Every 1000 hours

Take advantage of this operation to make a visual check of all the welded components (in case of any cracks), the attachment linkages and tooth mounting and wear.

Mark any leaks, check the condition of pipes and hoses.

CHANGING A BUCKET TOOTH TIP Tools required - Two 22 mm hexagonal wrenches Remove the two tooth retaining screws and remove the tooth.

TRIM THIS EDGE

Or whenever oil or grease has been spilt on the machine; clean such deposits off with steam or high pressure water jet.

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ADJUSTING THE ENGINE VALVE ROCKER CLEARANCES

PH02225

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Template Name: OM_1_col Template Date: 1994_04_29

NOTE : When installing, orientate the tooth in the correct direction.

MAINTENANCE/ADJUSTMENTS

TOOTH WEAR LIMITS The amount of tooth wear is inspected visually.

Template Name: OM_1_col Template Date: 1994_04_29

If the teeth are not worn symmetrically, their life-time can be extended by changing their positions on the bucket.

NOTE : Do not wait until a hole is worn in a tooth before changing it.

CHANGING A BUCKET Removal

STEP 3

STEP 1

Operate the attachment control lever to lower the attachment.

STEP 4

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CD97E043

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Park the machine on flat, horizontal ground, with the bucket parallel to and resting on the ground.

CD97E042

Move the machine backward.

STEP 2

PH03430A

Use the control lever to unlock the quick coupler cylinder.

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MAINTENANCE/ADJUSTMENTS

Installation

STEP 2

CD97E069

CD97E069

STEP 3 TRIM THIS EDGE

Line the machine up with the bucket so that the two ends of the quick coupler are in line with the lugs on the bucket.

Raise the attachment so that the bucket is raised from the ground and comes up against the stops on the quick coupler.

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STEP 1

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Template Name: OM_1_col Template Date: 1994_04_29

PH03430A

Lock the quick coupler cylinder using the control lever.

MAINTENANCE/ADJUSTMENTS

CHANGING A 4-IN-1 BUCKET Template Name: OM_1_col Template Date: 1994_04_29

Removal

STEP 4

STEP 1 Park the machine on flat, horizontal ground, with the bucket parallel to and resting on the ground.

STEP 2 Shut down the engine and operate the controls to release pressure in the system.

STEP 3

CD97E085

Disconnect the quick coupler cylinder hoses from the hydraulic rest couplings and install protective caps on the hydraulic rest couplings.

TRIM THIS EDGE

STEP 5

CD97E090

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Disconnect the 4-in-1 bucket clam cylinder hoses and install protective caps on the unions.

CD97E085

Connect the quick coupler cylinder hoses to the hydraulic supply couplings.

STEP 6 Start the engine.

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MAINTENANCE/ADJUSTMENTS

Installation

STEP 7

PH03430A

Use the control lever to unlock the quick coupler cylinder.

CD97E069

Line the machine up with the 4-in-1 bucket so that the ends of the quick coupler are in line with the 4-in-1 bucket lugs.

STEP 8

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STEP 2

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STEP 1

CD97E069

Lower the attachment to disengage the ends of the quick coupler and move the machine backward.

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Template Name: OM_1_col Template Date: 1994_04_29

CD97E069

Raise the attachment so that the 4-in1 bucket is off the ground and against the stops on the quick coupler.

MAINTENANCE/ADJUSTMENTS STEP 6

STEP 3

Template Name: OM_1_col Template Date: 1994_04_29

PH03430A

CD97E074

Lock the quick coupler cylinder using the control lever.

Connect the quick coupler hoses to the hydraulic rest couplings.

STEP 4

STEP 7

TRIM THIS EDGE

Shut down the engine and operate the controls to release pressure in the system.

STEP 5

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CD97E090

Connect the 4-in-1 bucket clam cylinder hoses.

CD97E085

Disconnect the quick coupler cylinder hoses from the hydraulic supply couplings.

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MAINTENANCE/ADJUSTMENTS

A cylinder rod should be slightly oily. Check for leaks after a working period, when the entire hydraulic system is at normal operating temperature.

1 Clean the rod and the gland of the cylinder which is to be inspected.

2 Work normally for 5 to 10 minutes.

3 Extend the cylinder rod.

ROD APPEARANCE

TEST

CONCLUSION

Dry

Slight traces of oil when a sheet of paper is rubbed over 20 cm of the rod.

Normal

Slightly oily

A sheet of paper remains stuck when run over the rod.

Normal

Oily

A sheet of paper placed on the rod stays stuck to it.

Normal

Very oily or weeping

A ring of oil is visible on the rod after each rod extension.

Leak

Oil drips from the gland every time the cylinder rod is retracted.

Template Name: OM_1_col Template Date: 1994_04_29

Consult your CASE Dealer

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4 Check for leaks.

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CHECKING THE CYLINDERS FOR LEAKS

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MAINTENANCE/ADJUSTMENTS

TROUBLESHOOTING INCIDENT

Template Name: OM_1_col Template Date: 1994_04_29

The starter motor does not turn the engine fast enough.

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The engine does not start.

POSSIBLE CAUSES

SOLUTIONS

Battery discharged

Recharge or replace battery

Bad contact at terminals, cables broken

Clean terminals or replace

Incorrect oil quality

Change the oil

Faulty starter motor

Consult your CASE Dealer

Empty fuel tank

Fill the fuel tank

Clogged fuel piping

Check and blow through lines

Dirty fuel filter

Change the filter

Air in fuel system

Locate and seal off the place where air is entering. Bleed the filter

Incorrect procedure for cold start assistance system

Start again

Polluted fuel

Drain and clean the fuel circuit

Incorrect rocker clearances Faulty starter motor switch Faulty injection pump

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Faulty injectors

Consult your CASE Dealer

Faulty pre-heat system Motor worn or damaged

The engine is hard to start.

Clogged fuel lines

Check and blow through lines

Dirty fuel filters

Change the filter

Dirty air filter

Clean the filter

Air in fuel system

Locate and seal off the place where air is entering. Bleed the filter

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INCIDENT

The engine is hard to start (cont.).

POSSIBLE CAUSES

SOLUTIONS

Incorrect procedure for cold start assistance system

Use correct starting procedure

Fuel tank breather orifice blocked

Clean the filler cap

Polluted fuel

Drain and clean the fuel circuit

Exhaust pipe blocked

Check

Incorrect rocker clearances Faulty starter motor Faulty starter motor switch Faulty injection pump

Consult your CASE Dealer

Faulty injectors Faulty pre-heat system

Engine lacks power.

Clogged fuel piping

Check and blow through lines

Dirty fuel filter

Change the filter

Dirty air filter

Clean the filter

Air in fuel system

Locate and seal off the place where air is entering. Bleed the filter

Fuel tank breather orifice blocked

Clean the filler cap

Polluted fuel

Drain and clean the fuel circuit

Blocked exhaust pipe

Check

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Faulty motor

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MAINTENANCE/ADJUSTMENTS

Faulty injectors Faulty speed selector control system Engine temperature too high.

Consult your CASE Dealer

Coolant solution level too low

Add coolant solution, check for leaks

Dirty air filter

Clean

Slack alternator/fan belt

Tighten belt

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Template Name: OM_1_col Template Date: 1994_04_29

Faulty injection pump

MAINTENANCE/ADJUSTMENTS INCIDENT

Template Name: OM_1_col Template Date: 1994_04_29

Engine temperature too high (cont.).

POSSIBLE CAUSES

SOLUTIONS

Dirty radiator

Blow through radiator fins

Clogged hoses

Inspect and replace clogged hoses

Engine oil level too high

Check

Exhaust pipe blocked

Check

Faulty radiator cap valve

Change the cap

Incorrect rocker clearances Faulty injector Damaged thermostat Faulty temperature sender

Consult your CASE Dealer

Water pump inoperative Damaged engine Faulty turbocharger

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Engine temperature too low.

Damaged thermostat Faulty temperature sender

Consult your CASE Dealer

Clogged fuel system

Check the lines, the fuel pump and the filter

Air in fuel system

Locate and seal the place where air is entering

Incorrect rocker clearances Engine misfires.

Faulty injector

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Damaged cold start assistance system

Consult your CASE Dealer

Faulty injection pump Damaged engine

Excessive fuel consumption.

Dirty air filter

Clean the filter

Unsuitable fuel quality

Drain the fuel tank and refill with suitable fuel

Exhaust pipe blocked

Check

Incorrect rocker clearances Faulty injector Faulty injection pump Damaged engine

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Consult your CASE Dealer

MAINTENANCE/ADJUSTMENTS

Black smoke at exhaust.

POSSIBLE CAUSES

SOLUTIONS

Dirty air filter

Clean the filter

Unsuitable fuel quality

Drain the fuel tank and refill with suitable fuel

Incorrect rocker clearances Faulty injector

Consult your CASE Dealer

Faulty injection pump Unsuitable engine oil quality Incorrect rocker clearances Blue or white smoke at Faulty cold start assistance system exhaust.

Faulty injection pump

Drain and refill the engine

Consult your CASE Dealer

The engine knocks.

Drain and refill the engine

Incorrect engine oil level

Adjust the oil level

Faulty oil pressure sender Damaged engine

Consult your CASE Dealer

Clogged fuel supply pump

Clean the pump

Incorrect fuel quality

Drain the fuel tank and refill with suitable fuel

Incorrect oil quality or level

Change oil or adjust level

Faulty injectors Faulty injection pump Incorrect rocker clearances

Consult your CASE Dealer

Damaged engine

Template Name: OM_1_col Template Date: 1994_04_29

Engine oil pressure too low.

Unsuitable engine oil quality

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Damaged engine

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INCIDENT

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MAINTENANCE/ADJUSTMENTS INCIDENT

Template Name: OM_1_col Template Date: 1994_04_29

POSSIBLE CAUSES

SOLUTIONS

Clogged fuel lines

Check and blow through lines

Clogged fuel supply pump

Clean the pump

Clogged air filter

Clean

Air in fuel system

Locate and seal off the place where air is entering. Bleed the filter

Fuel tank breather orifice blocked

Clean the filler cap

Unstable engine speed.

Incorrect engine oil quality or level Change oil or adjust level Faulty starter motor switch Faulty injectors Faulty injection pump

Consult your CASE Dealer

Damaged engine Faulty engine mountings

Check

TRIM THIS EDGE

Faulty injectors Engine vibration.

Damaged fan Faulty injection pump

Consult your CASE Dealer

Damaged engine Engine oil pressure too high.

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Engine starts and immediately stops.

Machine will not travel either forward or in reverse.

Incorrect oil quality

Drain and refill

Faulty oil pressure sender

Consult your CASE Dealer

Clogged fuel filter

Clean

Clogged air filter

Clean

Air in fuel system

Locate and seal off the place where air is entering. Bleed the filter

Hydraulic fluid level too low

Adjust the level

Faulty engine/hydraulic pump coupling Faulty electro-control valve

Consult your CASE Dealer

Faulty hydraulic pump Low tractive effort in forward and reverse first gear.

Electro-control valve locked in another speed

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Consult your CASE Dealer

Hydraulic fluid temperature too high.

POSSIBLE CAUSES

SOLUTIONS

Incorrect level or quality of fluid

Adjust the level or change fluid

Hydraulic oil cooler clogged

Clean oil cooler fins

Faulty hydraulic pump

Consult your CASE Dealer

Faulty hydraulic motor The machine cannot Electro-control valve locked in first reach maximum speed. or second

Consult your CASE Dealer

Faulty electro-control valve electrical supply

Consult your CASE Dealer

Slow cylinder movement.

Faulty hydraulic pump

Consult your CASE Dealer

Hydraulic oil level too low

Adjust the level

Air in the system

Check condition of lines and tightening of clamps

Faulty hydraulic pump

Consult your CASE Dealer

Damaged seal

Consult your CASE Dealer

Noisy hydraulic pump.

Oil leak at cylinders.

Template Name: OM_1_col Template Date: 1994_04_29

The machine decelerates jerkily.

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INCIDENT

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MAINTENANCE/ADJUSTMENTS

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ELECTRICAL SYSTEM

FUSES Left-hand box Template Name: OM_1_col Template Date: 1994_04_29

12 6

11 10 9

5 7 1 2

8

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3 4

CD97E088

IMPORTANT : Never replace a fuse by a fuse of a different amperage.

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1 2 3 4 5 6 7

Alternator (D+) ...................................................................................7.5 amps Speed selector - reverse travel audible warning device......................20 amps Direction indicator ...............................................................................20 amps Rotary light - inspection lamp (121B Series) ......................................20 amps Heater .................................................................................................25 amps Horn ....................................................................................................15 amps Pre-heat and neutral indicator lamps, brake fluid level, parking brake, steering pressure warning lamps, audible warning device, monitoring panel, fuel level gauge, engine shut control..............................................................................20 amps 8 Cab interior light, radio (optional) .......................................................7.5 amps 9 Air conditioning (optional)....................................................................25 amps 10 Windshield washer .............................................................................7.5 amps 11 Rear windshield wiper ........................................................................7.5 amps 12 Front windshield wiper ........................................................................20 amps

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ELECTRICAL SYSTEM

19

17

13 18

24

20 22

CD97E089

IMPORTANT : Never replace a fuse by a fuse of a different amperage.

13 14 15 16 17 18

19 20 21 22 23 24

Right-hand direction indicator.............................................................7.5 amps Left-hand direction indicator, flasher indicator lamp ...........................7.5 amps Right-hand stop light ..........................................................................7.5 amps Left-stop brake light............................................................................7.5 amps Front right-hand, rear left-hand sidelight front and rear working light relays ......................................................7.5 amps Front left-hand, rear right-hand sidelights sidelight indicator lamp - hazard warning light switch, front windshield wiper, hourmeter lighting, speedometer and fuel level gauge .....................................................7.5 amps Right-hand dipped headlight ..............................................................7.5 amps Left-hand dipped headlight.................................................................7.5 amps Left-hand main-beam headlight..........................................................7.5 amps Right-hand main-beam headlight - headlight indicator lamp ..............7.5 amps Rear working light - cab upright switch lighting ...................................20 amps Front working light ...............................................................................20 amps

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21

23

Template Name: OM_1_col Template Date: 1994_04_29

16

15

14

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Right-hand box

ELECTRICAL SYSTEM

STARTER MOTOR FUSE

CD97E098

Template Name: OM_1_col Template Date: 1994_04_29

This 50 amp fuse is located on top of the starter motor.

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ELECTRICAL SYSTEM

WARNING : When the electrolyte of a battery is frozen, it can explode if you attempt to charge the battery or if you try to start the engine using a booster battery. Always keep the battery charged to prevent the electrolyte freezing.

WARNING : Batteries produce explosive gases. Keep all flames, sparks and cigarettes away from a battery. When charging or using a battery in an enclosed space, always provide good ventilation. Always protect your eyes when working near a battery.

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Template Name: OM_1_col Template Date: 1994_04_29

WARNING : Battery electrolyte causes severe burns. The battery contains sulphuric acid. Avoid contact with the skin, the eyes or clothing.

Antidote : EXTERNAL : Rinse with water.

INTERNAL : Drink large quantities of water or milk. Then drink milk of magnesia, a beaten egg or vegetable oil. Call a doctor immediately.

EYES : Rinse with water for 15 minutes and consult a doctor quickly.

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WARNING : A spark or flame can cause the hydrogen in a battery to explode. To prevent any risk of explosion, observe the following instructions : - Always disconnect the negative cable (-) first when disconnecting battery cables.

- Always connect the negative cable (-) last when reconnecting battery cables.

- Never short-circuit the battery terminals with metal objects.

- Put the terminal covers back in place during any maintenance operation.

- Do not weld, grind or smoke near a battery.

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BATTERY

ELECTRICAL SYSTEM

Service specifications Electrolyte level inspection............................................................ Every 100 hours

Template Name: OM_1_col Template Date: 1994_04_29

Access to the battery

Checking the electrolyte level

STEP 1

CD97E021

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Raise the loader attachment, install the attachment locking bar, lock the attachment controls, shut down the engine and remove the starter switch key.

STEP 2

CD97E011

Remove the battery caps and check the level in each cell of the battery. The level should reach the split ring located at the bottom of each cell opening.

Top up if necessary with distilled water.

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IMPORTANT : If the temperature is 0°C or below and you have added water to the battery, proceed in the following manner : Connect a battery charger to the battery or run the engine for about two hours.

This procedure is necessary to mix the water inside the battery.

CD97E020

Remove the two knobs and the front panel.

Check that the connecting terminals are clean and coated with grease and that the cables are correctly tightened.

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Replacing a battery

Installation

Tools required

Put the new battery in place. Install the retaining plate.

- One 13 mm hexagonal wrench

Clean the cables and the connecting terminals and coat them with grease.

Connect the cables (first the positive terminal, then the negative terminal) and install the terminal covers.

Template Name: OM_1_col Template Date: 1994_04_29

Remove the terminal covers and disconnect the battery cables (first the negative terminal, then the positive terminal).

Remove the retaining plate, then remove the battery.

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CD97E086

Removal

WARNING : Never reverse the battery terminals. Connect the positive cable to the positive terminal (+) and the negative cable to the negative terminal (-).

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ELECTRICAL SYSTEM

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ELECTRICAL SYSTEM

CONNECTING A BOOSTER BATTERY Template Name: OM_1_col Template Date: 1994_04_29

WARNING : Connecting jumper cables wrongly or short-circuiting battery terminals can cause an accident. Connect the jumper cables following the instructions in this manual.

Tools required - Jumper cables Make sure that the voltage of the booster batteries is the same as that of the machine circuit (12 volts).

STEP 1

STEP 5

To gain access to the battery, see "Battery access".

Start the engine.

STEP 2

STEP 6 First disconnect the negative (-) jumper cable, then disconnect the positive (+) jumper cable from the booster battery.

Remove the terminal covers.

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STEP 3 Connect the positive (+) jumper cable to the positive (+) terminal of the machine’s battery.

STEP 7 Install the terminal covers.

STEP 4

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Connect the negative (-) jumper cable to the negative (-) terminal of the machine’s battery.

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ELECTRICAL SYSTEM

ALTERNATOR Inspection.................................................................................... Every 1000 hours IMPORTANT : before welding on the machine or making any repairs to the electrical system, disconnect the alternator plug.

IMPORTANT : Do not use steam of a solvent to clean the alternator.

CD97E076

STARTER MOTOR Service specifications

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Have the alternator checked by your CASE Dealer.

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Service specifications

Inspection.................................................................................... Every 1000 hours

CD97E073

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Template Name: OM_1_col Template Date: 1994_04_29

Have the starter motor checked by your CASE Dealer.

ELECTRICAL SYSTEM

INJECTORS Service specifications Template Name: OM_1_col Template Date: 1994_04_29

Inspection.................................................................................... Every 2000 hours Have the injectors checked by your CASE Dealer.

CD97E057

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BULBS

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Power Control panel indicator/warning lamps ........................................................... 1.2 W Operator’s compartment light.......................................................................... 10 W Headlights (dipped and main beam) .......................................................... 70/75 W Front and rear working lights .......................................................................... 70 W Front and rear direction indicators .................................................................. 21 W Front sidelights.................................................................................................. 5 W Rear lights/stop lights................................................................................5W/21 W Rotary light ...................................................................................................... 70 W

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ELECTRICAL SYSTEM

STEP 1

CD97E012

Remove the lens.

CK97E002

Remove the silk-screen printed panel (1) and the indicator/warning lamp support block (2).

STEP 2

STEP 2 Remove the indicator/warning lamp block bulb holder.

STEP 3 Remove the bulb and replace it by a bulb of the same wattage (1.2 W).

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STEP 1

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Cab light

REPLACING A BULB Control panel

CD97E072

Remove the bulb and replace it by a bulb of the same wattage (10 W).

STEP 3 Install the lens.

Install the bulb holder on the indicator/ warning lamp block.

STEP 5 Install the indicator/warning lamp support block in its housing and install the silkscreen printed panel.

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Template Name: OM_1_col Template Date: 1994_04_29

STEP 4

ELECTRICAL SYSTEM

Template Name: OM_1_col Template Date: 1994_04_29

Headlights and sidelights

STEP 4

Tools required

Press the clips (4) back into place.

- One cross-pattern ended screwdriver.

STEP 5

STEP 1

Reconnect the plug (2) to the bulb base and install the sidelight bulb holder (3).

STEP 6 Install the light unit and fasten it with its screws.

Front direction indicator Tools required - One cross-pattern ended screwdriver.

STEP 1 PH03534

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Remove the four screws and remove the light unit.

STEP 2

4

2 1

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PH01811

3

Remove the screws and the lens.

PH01816

Remove the sidelight bulb holder (3) and replace the bulb by a bulb of the same wattage (5 W). Disconnect the plug (2) from the bulb base.

STEP 3 Raise the clips (4) and remove the bulb.

Replace it by a bulb of the same wattage (70/75 W).

IMPORTANT : Never touch a quartz iodine bulb with your fingers.

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ELECTRICAL SYSTEM

PH01813

STEP 3 Install the lens and fasten it with its screw.

Rear lights

CD97E070

Remove the bulbs and replace them by bulbs of the same wattage: Sidelights and stop lights (5W/20W).

Direction indicators (21 W).

STEP 3 Install the lens and the screws.

Tools required

Front and rear working lights

- One cross-pattern ended screwdriver.

STEP 1

Tools required - One cross-pattern ended screwdriver.

- One small flat-ended screwdriver

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Remove the bulb and replace it by a bulb of the same wattage (21 W).

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STEP 2

STEP 2

CD97E071

Remove the screws and the lens.

PH01825

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Template Name: OM_1_col Template Date: 1994_04_29

STEP 1

ELECTRICAL SYSTEM

Rotary light Tools required Template Name: OM_1_col Template Date: 1994_04_29

- One cross-pattern ended screwdriver.

STEP 1

1

CD97E024

Remove the two screws and remove the light unit.

2

STEP 2 CD97E094

1 TRIM THIS EDGE

Remove the three screws (2) and remove the lens (1).

STEP 2

2

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PH01829

Disconnect the electric cable from the connection block (1) and raise the clip (2).

STEP 3 Remove the bulb and replace it by a bulb of the same wattage (70 W).

IMPORTANT : Never touch a quartz iodine bulb with your fingers.

CD97E095

Raise the clip and remove the bulb.

STEP 3

STEP 4

Replace the bulb by a bulb of the same wattage (70 W).

Install the light unit and fasten it with its screws.

IMPORTANT : Never touch a quartz iodine bulb with your fingers.

STEP 4 Install the lens and fasten with its three screws.

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ELECTRICAL SYSTEM

ADJUSTING THE HEADLIGHTS - One flat-ended screwdriver.

The headlights are adjusted by means of two screws. Turn the upper screw for vertical adjustment and the lower screw for horizontal adjustment.

Template Name: OM_1_col Template Date: 1994_04_29

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PH03534

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Tools required

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STORAGE

STORING THE MACHINE Preparation for storage Template Name: OM_1_col Template Date: 1994_04_29

If the machine is to remain unused for a period exceeding 30 days, store it under cover or cover it with a waterproof tarpaulin.

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1.

Clean the machine.

2.

Grease all the machine’s grease fittings.

3.

Drain the fuel tank.

4.

Pour about 8 litres of rinsing fuel in the fuel tank. Run the engine until the exhaust smoke is a bluish white colour.

5.

Put a tablespoonful of Shell Oil Company VPI crystals in the fuel tank.

6.

Operate all the hydraulic controls to release pressure in the hydraulic circuits.

7.

Drain the engine oil and replace the oil filter.

8.

Drain the cooling system. Leave the drain valves open and do not tighten the radiator cap. Place a "Do not start up" label in the operator’s compartment.

9.

Clean or replace the air filter element.

10. Coat the exposed portions of the cylinder rods and control valve spools with Case anti-corrosion grease.

11. Paint all parts of the machine where the paint has been damaged.

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12. Charge the battery. Remove it from the machine and place it on a wooden pallet in a cool, dry place. If possible, store it in a place where the temperature is above 0°C. Make sure it is clean.

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STORAGE

Starting up after storage 1.

Replace the fuel filter.

2.

Pour coolant solution into the engine cooling system.

3.

Check the condition of the alternator belt. Replace it if necessary.

4.

Fill the engine with oil and check the engine oil level.

5.

Check the hydraulic fluid level.

6.

Check the oil level in the axles and reduction gears.

7.

Check the oil level in the hydraulic transmission.

8.

Grease all the machine’s linkages.

9.

Use a paraffin based solvent to remove the CASE anti-corrosion protection from the hydraulic cylinders.

11. Fill the fuel tank.

12. Bleed air from the fuel supply system.

13. Check the condition and pressure of the tyres.

14. Start the engine.

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10. Install the battery.

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Do not start the engine before carrying out the following operations :

WARNING : Before starting the engine, make sure all the controls are in the neutral position. This will prevent any unexpected movement of the machine and of any electrical equipment.

WARNING : Avoid running the engine in an enclosed space. Ensure adequate ventilation at all times.

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Template Name: OM_1_col Template Date: 1994_04_29

WARNING : Check the machine for leaks and for broken, defective or missing parts.

SPECIFICATIONS

ENGINE Template Name: OM_1_col Template Date: 1994_04_29

Make and model ............................................................................. Perking 704-30 Maximum S.A.E. horsepower........................................61 hp (45 kW) at 2400 rpm Maximum DIN 6271 horsepower...................................58 hp (43 kW) at 2400 rpm Maximum EEC 80/1269 horsepower ............................58 hp (43 kW) at 2400 rpm Maximum ISO 9249 horsepower...................................58 hp (43 kW) at 2400 rpm EEC 80/1269 maximum torque ...............................................205 Nm at 1600 rpm Displacement ........................................................................................... 2955 cm3 Number of cylinders .............................................................................................. 4 Bore and stroke...................................................................................97 x 100 mm Compression ratio ..................................................................................... 17.5 to 1 Injection system ..............................................................................................direct Air filter ........................................................................................................dry type Restriction indicator ................................................................ on instrument panel Oil filter ................................................................................ screw-on element type

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Voltage ........................................................................................................ 12 volts Battery................................................................................................... 1 x 12 volts Alternator ...................................................................................................45 amps

SOUND LEVELS

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Guaranteed by the manufacturer.

In accordance with European directive 86/662/EEC. Inside operator’s compartment (LpA) ................................................... 73 decibels Outside machine (LwA) ........................................................................ 99 decibels

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SPECIFICATIONS

Type : hydrostatic type with automatic closed circuit power regulation.

A single electrically controlled lever selects the two forward and reverse speeds and the direction of travel of the machine.

Hydraulic system Variable flow piston pump, with forced feed pump, bolted to the engine, direct driven from the engine.

Dual displacement, piston motor.

10 micron interchangeable filter, on the inlet circuit, with restriction indicator of the instrument panel.

Oil pressure ................................................................................................. 440 bar

Engine at full speed Forward/reverse travel ................................................................ first speed : 9 kph second speed : 24 kph (special for Germany) : 20 kph Inching pedal........................................................... Precise control of travel speed

AXLES Front drive axle .................................................................................................rigid Rear drive axle ......................................................................... oscillating (+, -) 25° Limited slip differentials ..................................................... on front and/or rear axle (standard or optional equipment, depending on country concerned)

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Travel speeds

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TRANSMISSION

121B Series Standard....................................................................................................12.5 x 20

221B Series Standard................................................................................................405/70 x 18

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Template Name: OM_1_col Template Date: 1994_04_29

TYRES

SPECIFICATIONS

BRAKES Service brakes Template Name: OM_1_col Template Date: 1994_04_29

Disc brake on transmission shaft

Parking brake Manually controlled band brake mounted on the front axle drive drop box output shaft

STEERING 121B Series

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Type ....................................................................................................... hydrostatic Turning angle ............................................................................................ (+, -) 40° Turning radius: Tyre inner................................................................................................. 2.10 m Bucket outer............................................................................................. 4.20 m Steering cylinders .............................................................................. double acting Diameter x stroke............................................................................65 x 255 mm Pump........................................................................................................ gear type Flow .................................................................................................. Load Sensing Main relief valve pressure setting................................................................ 175 bar

221B Series

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Type ....................................................................................................... hydrostatic Turning angle ............................................................................................ (+, -) 40° Turning radius: Tyre inner................................................................................................. 2.05 m Bucket outer............................................................................................. 4.25 m Steering cylinders .............................................................................. double acting Diameter x stroke............................................................................65 x 255 mm Pump........................................................................................................ gear type Flow .................................................................................................. Load Sensing Main relief valve pressure setting................................................................ 175 bar

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SPECIFICATIONS

Two-body gear pump, mounted directly on the end of the transmission pump, directly driven from the engine.

Flow for attachment............................................................... 64 L/min at 2400 rpm Flow for steering system, priority - Load Sensing type Open centre control valves, with three modular type spools, controlled by a cross-pattern control lever, with floating position.

Maximum working pressure .................................................................... 230 bar Double acting cylinders with hardened and chromed cylinder rods.

Arm (quantity 2) (diameter x stroke) ...............................................70 x 586 mm Bucket (quantity 1) (diameter x stroke) ...........................................80 x 405 mm Oil reservoir, common to the transmission system.

Cycle times Raising (full bucket) ......................................................................... 4.7 seconds Lowering (empty bucket).................................................................. 3.2 seconds Dumping........................................................................................... 1.5 seconds Complete cycle time......................................................................... 9.4 seconds

CAPACITIES Fuel tank .......................................................................................................... 60 L

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Filtration on return circuit by 10 micron filter with interchangeable element.

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HYDRAULIC SYSTEM

Engine with filter .............................................................................................. 5.5 L Axle Front.......................................................................................................... 10.5 L Rear .......................................................................................................... 10.5 L Reduction gear (each) ................................................................................ 2.2 L Braking system................................................................................................ 1.1 L Cooling system................................................................................................. 12 L

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Template Name: OM_1_col Template Date: 1994_04_29

Hydraulic system: Total ............................................................................................................. 70 L Hydraulic reservoir ....................................................................................... 50 L

SPECIFICATIONS

PERFORMANCE AND SPECIFICATIONS 121B Series Template Name: OM_1_col Template Date: 1994_04_29

Performance Standard bucket capacity............................................................................0.70 m3 Standard bucket weight ................................................................................300 kg Break-out force ........................................................................................ 5150 daN Tipping load (without quick coupler), with standard bucket: In line ......................................................................................................3100 kg Turned 40° ..............................................................................................2750 kg

Dimensions and weights

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Track ............................................................................................................ 1.38 m Ground clearance ........................................................................................ 0.32 m Overall width to tyre outers .......................................................................... 1.72 m Bucket width................................................................................................. 1.80 m Standard all-up weight ................................................................................4450 kg Maximum all-up weight ...............................................................................4750 kg

221B Series

Performance

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Standard bucket capacity............................................................................0.80 m3 Standard bucket weight ................................................................................320 kg Break-out force ........................................................................................ 5150 daN Tipping load (without quick coupler), with standard bucket: In line ......................................................................................................3500 kg Turned 40° ..............................................................................................3150 kg

Dimensions and weights Track ............................................................................................................ 1.38 m Ground clearance ........................................................................................ 0.32 m Overall width to tyre outers .......................................................................... 1.80 m Bucket width................................................................................................. 1.90 m Standard all-up weight ................................................................................4800 kg Maximum all-up weight ...............................................................................5000 kg

Electric speed selection A single lever located near the steering wheel controls the electric selection of speeds and the direction of travel.

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SPECIFICATIONS

A single cross-pattern control lever for the attachment functions.

The second lever is provided for locking the bucket or for 4-in-1 bucket clam control.

Electronic monitoring system A complete instrument panel is located in front of the operator.

Visible and audible warning devices accompany the main functions of the machine.

Super comfort cab The cab is mounted on flexible mountings. It is to ROPS and FOPS standards, is sound-proofed and has a large area of safety glass, providing total visibility.

Operator’s seat with adjustable suspension.

High performance heating and ventilation.

Hydraulically controlled quick coupler

Quick access

Template Name: OM_1_col Template Date: 1994_04_29

The engine hood can be tilted back providing total access for inspection and maintenance of the main components.

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The hydraulically controlled quick coupler, standard or optional (depending on the country concerned), enables buckets and other tools to be changed in a few seconds.

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Smooth controls

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SPECIFICATIONS

STANDARD OR OPTIONAL ACCESSORIES (depending on country concerned) Template Name: OM_1_col Template Date: 1994_04_29 TRIM THIS EDGE

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Cab homologated to ROPS and FOPS standards.

Two access doors.

Adjustable suspension type operator’s seat with seat belt.

Ventilation.

Heating and defrosting.

Sound-proofing to European standards.

Front and rear working lights.

Road lights.

Front and rear windshield wipers.

Left and right-hand rear-view mirrors.

Horn.

Reversing audible warning device.

Instrument panel with electronic monitoring system Audible warning device (failures in main functions) Visual bucket position indicator Safety bar on attachment.

Three-spool control valve.

Hydraulically or mechanically controlled quick coupler.

Lockable filler caps for the fuel tank and hydraulic fluid reservoir.

Towing eye.

Sling points.

Counterweight.

Steering wheel handle.

Sun-visor.

Rotary light.

"Inching" pedal

Fourth function hydraulics.

Limited slip differentials on front and/or rear axles.

Radio pre-equipment.

Air conditioning.

4-in-1 bucket.

Lightweight materials bucket.

Earthmoving bucket.

High dump height bucket.

Side dump bucket.

Pallet forks.

Adjustable angle dozer blade.

Paper grab.

Sweeper.

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Template Name: OM_1_col Template Date: 1994_04_29

CS97F030

CS97F031

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SPECIFICATIONS

MACHINE OVERALL DIMENSIONS AND WORKING RANGE

ALPHABETICAL INDEX

Template Name: OM_1_col Template Date: 1994_04_29

A

E

Air conditioning ................................. 57 Air filter ............................................ 109 Alternator ........................................ 151 Attachment control lever ................... 48 Attachment control locking knob ....... 49 Audible warning device cut-out push-button................................... 40 Axles ............................................... 161 Axles and reduction gears .............. 117

Electrical system............................. 160 Engine..................................... 101, 160 Engine air filter red warning light ...... 41 Engine alternator and fan belt......... 128 Engine coolant solution temperature red warning lamp ..... 41 Engine green symbol ........................ 40 Engine hood...................................... 59 Engine hood opening control handle........................................... 50 Engine oil pressure red warning lamp ................................ 41 Engine pre-heat orange indicator lamp ............................... 43 Environment...................................... 90

B

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Battery............................................. 147 Battery red warning lamp .................. 41 Before operating the machine ........... 61 Brake fluid reservoir .......................... 50 Brake pedal ....................................... 47 Brakes ..................................... 123, 162 Braking system pressure red warning lamp .......................... 43 Bucket locking or 4-in-1 bucket clam control lever .............. 48 Bulbs ............................................... 152 C

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Cab doors ......................................... 38 Cab light ............................................ 51 Cab ventilation inlet filter ................. 112 Cab ventilation inlet filter compartment................................. 51 Capacities ....................................... 163 Changing a 4-in-1 bucket ................ 134 Changing a bucket .......................... 132 Changing a bucket tooth tip ............ 131 Connecting a booster battery .......... 150 Control panel..................................... 42 Control switches................................ 44 Cooling system ............................... 103 D Decals ............................................... 24 Direction indicator and road light control 46 Direction indicator green indicator lamp .............................................. 42

F Fire extinguisher ............................... 53 Fluid and lubricant capacities and specifications......................... 91 Fluids and lubricants......................... 88 Front panel........................................ 60 Front windshield wiper and windshield washer control ............ 44 Front working light control................. 44 Fuel level gauge ............................... 45 Fuel system .................................... 106 Fuel tank ........................................... 58 Fuses .............................................. 144 G Grease points ................................... 92 H Hand signals ..................................... 34 Hazard warning light control ............. 44 Heating and ventilation ..................... 56 Hourmeter......................................... 83 Hourmeter and speedometer............ 45 Hydraulic system .................... 113, 163 I Identification of the main components.................................. 12 Injectors .......................................... 152

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R

Inspection light socket.......................52 Instructions for use............................76

Right, left, front and rear of the machine 9 Road travel ....................................... 77 Rotary light control ............................ 44 Rotary light socket ............................ 52 Running-in period ............................. 64

Job site travel ....................................79 L Levels................................................98 Lighting control..................................47 Loader operating instructions ............79 M Machine overall dimensions and working range ......................167 Machine tools ....................................60 Main-beam headlight blue indicator lamp................................43 Monitoring panel................................40 O Official documents...............................7 Operating the machine......................62 Operating the machine in cold weather .........................................68 Operating the machine in hot weather .........................................69 Operating the machine in water ........75 Operator’s compartment controls ......45 P Parking brake lever ...........................49 Parking brake red warning lamp .......43 Parking the machine .........................75 Performance and specifications ......164 R Radiator and oil cooler ....................127 Radio.................................................53 Raising the sun-shield.......................52 Rear view mirrors ..............................57 Rear window .....................................55 Rear windshield wiper and windshield washer control.............44 Rear working light control..................44 Replacing a bulb .............................153

S Safety instructions ............................ 13 Servicing instructions ........................ 82 Side light and dipped headlight green indicator lamp ..................... 42 Sound levels ................................... 160 Speed selector and audible warning device.............................. 46 Speed selector position green indicator lamp ............................... 42 Speed selector position yellow indicator lamp ............................... 42 Standard or optional accessories...... 166 Starter motor ................................... 151 Starter motor fuse ........................... 146 Starter switch .................................... 45 Starting the engine............................ 65 Steering .......................................... 162 Steering pressure red warning lamp.............................................. 43 Steps and access handles ................ 39 Storage compartment ....................... 51 Storing the machine ........................ 158 Sun-shield ......................................... 52 T To the owner ....................................... 6 Tooth wear limits............................. 132 Towing .............................................. 73 Towing ring ....................................... 58 Transmission .................................. 161 Transmission oil filter red warning lamp ................................ 41 Transmission oil temperature red warning lamp ................................ 41 Transmission orange symboL........... 40 Transporting the machine ................. 70 Travel control pedal .......................... 47

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J

Template Name: OM_1_col Template Date: 1994_04_29

I

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ALPHABETICAL INDEX

ALPHABETICAL INDEX T

Template Name: OM_1_col Template Date: 1994_04_29

Troubleshooting .............................. 138 Type, serial number and year of manufacture of the machine ......... 10 Tyres ............................................... 161 W Wheel chock ..................................... 60 Wheels and tyres ............................ 125 Windshield washer reservoir ............. 50

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NOTE : The CASE Company reserves the right to modify without prior notification the characteristics and design of the machine with no obligation to modify machines already sold.

All information given in this manual is based on technical date available at the time of going to print.

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You can obtain manuals on the operation, maintenance and repair of your machine from your CASE Dealer. To ensure quick and efficient service, consult your CASE Dealer for assistance in ordering the correct manuals for your machine.

Your CASE Dealer can deal with orders for operator’s manuals, parts catalogues and service manuals.

Template Name: OM_1_col Template Date: 1994_04_29

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Always give the type and serial number of your machine so that your CASE Dealer can supply you with the right manuals for your machine.

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CASE TECHNICAL MANUALS

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Template Name: OM_1_col Template Date: 1994_04_29

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printed in U.K.

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