Case 595SLE & 595LSP Loader Backhoe Operator's Manual 6-8940 - PDF DOWNLOAD

Operator’s Manual

Cre 6-8940 GB

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595SLE and 595LSP Loader Backhoes Alt= to hide template information Alt+ to display template information

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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 6-8940 GB Copyright  1999 Case France Issued May 1999

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IDENTIFICATION NUMBERS/MACHINE COMPONENTS ........................... 9 - 15 TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE ...................................................................................... 9 IDENTIFICATION OF MAIN COMPONENTS................................................ 12

CONTROLS/INSTRUMENTS/ACCESSORIES ......................................... 52 - 116 CAB DOORS ................................................................................................. 52 STEPS AND ACCESS HANDLES................................................................. 53 INSTRUMENT PANEL................................................................................... 54 OPERATOR’S COMPARTMENT CONTROLS ............................................. 58 OPERATOR’S SEAT ..................................................................................... 74 LOADER ATTACHMENT CONTROLS (595SLE type).................................. 77 BACKHOE ATTACHMENT CONTROLS (595SLE type) ............................... 81 LOADER ATTACHMENT AND BACKHOE ATTACHMENT CONTROLS (595LSP type)............................................................................................ 88 STABILIZER CONTROLS............................................................................ 100 HEATING, VENTILATION AND AIR CONDITIONING CONTROLS............ 102 OPERATOR’S COMPARTMENT WINDOWS ............................................. 105 REAR VIEW MIRRORS............................................................................... 107 FRONT AND REAR WINDSHIELD WASHER RESERVOIR ...................... 107 FUEL TANK ................................................................................................. 108 HYDRAULIC RESERVOIR .......................................................................... 109 BATTERY MASTER SWITCH ..................................................................... 110 BATTERY BOX............................................................................................ 110 LOADER ATTACHMENT SUPPORT STRUT ............................................. 111 ENGINE BONNET ....................................................................................... 112 RIDE CONTROL SYSTEM .......................................................................... 113 ROTATING BEACONS................................................................................ 114 TOOL BOX................................................................................................... 114 WHEEL CHOCK .......................................................................................... 115 TOOLING..................................................................................................... 115 BACKHOE ATTACHMENT AUXILIARY HYDRAULIC TOOL CONTROLS.............................................................................................. 116 OPERATING INSTRUCTIONS ................................................................ 117 - 161 BEFORE OPERATING THE MACHINE ...................................................... 117 OPERATING THE MACHINE ...................................................................... 118 RUNNING-IN PERIOD................................................................................. 120 1

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SAFETY/DECALS/HAND SIGNALS ........................................................... 16 - 50 SAFETY INSTRUCTIONS ............................................................................. 16 DECALS......................................................................................................... 27 HAND SIGNALS ............................................................................................ 46

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TO THE OWNER ............................................................................................ 5 - 8 595SLE AND 595LSP LOADER BACKHOES ................................................. 5 TO THE OWNER ............................................................................................. 6 RIGHT, LEFT, FRONT, AND REAR OF THE MACHINE.................................. 8

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TABLE OF CONTENTS

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Operating instruction (continued) STARTING THE ENGINE............................................................................

STARTING UP IN NORMAL CONDITIONS ................................................

STARTING UP SAFETY DEVICES.............................................................

ELECTRONIC SYSTEM ..............................................................................

STOPPING THE ENGINE ...........................................................................

OPERATING THE MACHINE IN COLD WEATHER ...................................

OPERATING THE MACHINE IN HOT WEATHER......................................

SETTING THE MACHINE IN THE BACKHOE ATTACHMENT WORKING POSITION.............................................................................

BACKHOE ATTACHMENT SIDESHIFT......................................................

SETTING THE BACKHOE ATTACHMENT IN THE ROAD TRAVEL POSITION.................................................................................

REPLACING A BACKHOE BUCKET ..........................................................

REMOVAL AND INSTALLATION OF QUICK ATTACH LOADER BUCKET .................................................................................

DIFFERENTIAL LOCK ................................................................................

BACKHOE ATTACHMENT AUXILIARY HYDRAULIC TOOLS ...................

LOAD LIFTING ............................................................................................

MAXIMUM WORKING LOADS....................................................................

LOADER BUCKET MOUNTED FORKS......................................................

TRANSPORTING THE MACHINE ..............................................................

LIFTING THE MACHINE .............................................................................

TOWING THE MACHINE ............................................................................

OPERATING THE MACHINE IN WATER ...................................................

PARKING THE MACHINE...........................................................................

MANUAL OPERATION OF THE STEERING CONTROL VALVE ...............

MANUAL OPERATION OF THE LOADER ARMS ......................................

MANUAL OPERATION OF THE BACKHOE ATTACHMENT (595LSP) .....

122 125 126 127 132 133 133 134 137 138 140 142 145 147 148 149 150 153 156 157 157 158 159 160 161

JOB SITE AND ROAD INSTRUCTIONS ................................................ 162 - 176 INSTRUCTIONS FOR USE......................................................................... 162 ROAD TRAVEL ........................................................................................... 163 JOB SITE TRAVEL ...................................................................................... 168 LOADER ATTACHMENT OPERATING INSTRUCTIONS .......................... 170 BACKHOE ATTACHMENT OPERATING INSTRUCTIONS ........................ 174 SERVICING INTERVALS ........................................................................ 177 - 181 SERVICING INSTRUCTIONS ..................................................................... 177 HOURMETER.............................................................................................. 178 INTERVALS ................................................................................................. 179 LUBRICATION/FILTERS/FLUIDS .......................................................... 182 - 240 FLUIDS AND LUBRICANTS........................................................................ 182 ENVIRONMENT .......................................................................................... 184 PLASTIC AND RESIN PARTS .................................................................... 185 FLUID AND LUBRICANT CAPACITIES ...................................................... 185 GREASE POINTS ....................................................................................... 186 LEVELS ....................................................................................................... 198 ENGINE ....................................................................................................... 201 2

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ELECTRICAL SYSTEM.......................................................................... 272 - 287 FUSES AND RELAYS ................................................................................. 272 BATTERY .................................................................................................... 276 CONNECTING A BOOSTER BATTERY ..................................................... 279 ALTERNATOR............................................................................................. 280 STARTER MOTOR...................................................................................... 280 CHECKING ELECTRICAL HARNESSES.................................................... 281 BULBS ......................................................................................................... 281 REPLACING A BULB .................................................................................. 282 VERTICAL ADJUSTMENT OF THE CAB-MOUNTED FRONT AND REAR WORKING LIGHTS ............................................................. 287 STORAGE ............................................................................................... 288 - 289 STORING THE MACHINE........................................................................... 288

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MAINTENANCE/ADJUSTMENTS.......................................................... 241 - 271 WHEELS AND TYRES ................................................................................ 241 LOADER BUCKET RETURN-TO-DIG ADJUSTMENT................................ 243 RADIATOR AND OIL COOLER................................................................... 244 ENGINE ALTERNATOR AND FAN BELT ................................................... 245 ENGINE VALVE TIP CLEARANCE ADJUSTMENT.................................... 246 MACHINE INSPECTION AND CLEANING ................................................. 246 CYLINDER LEAK INSPECTION.................................................................. 247 AIR CONDITIONING ................................................................................... 248 AIR INTAKE FILTER CAB HEATER............................................................ 250 PARKING BRAKE INSPECTION AND ADJUSTMENT............................... 252 BRAKE CHECK ........................................................................................... 254 RIDE CONTROL SYSTEM ACCUMULATOR ............................................. 255 ROPS/FOPS CAB........................................................................................ 256 STEERING AND AXLES ............................................................................. 258 TRANSMISSION.......................................................................................... 259 FUEL INJECTORS ...................................................................................... 259 TURBO-CHARGER ..................................................................................... 260 EXTENDABLE DIPPER............................................................................... 261 REPLACING A STABILIZER PAD............................................................... 264 REPLACING A BACKHOE BUCKET OR LOADER BUCKET TOOTH ....... 265 ENGINE TROUBLESHOOTING .................................................................. 268

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205 210 217 220 225 230 235 239

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Lubrication/Filters/Fluids (continued) COOLING SYSTEM.....................................................................................

FUEL SYSTEM ............................................................................................

RELEASING THE PRESSURE IN THE HYDRAULIC SYSTEM .................

HYDRAULIC SYSTEM ................................................................................

AIR FILTER..................................................................................................

TRANSMISSION..........................................................................................

FRONT AND REAR AXLES AND REDUCTION GEARS............................

BRAKE FLUID .............................................................................................

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SPECIFICATIONS ................................................................................... 290 - 299 ENGINE ....................................................................................................... 290 ELECTRICAL SYSTEM............................................................................... 290 CAB ............................................................................................................. 290 MACHINE WEIGHT..................................................................................... 290 TRANSMISSION ......................................................................................... 291 AXLES ......................................................................................................... 292 TYRES......................................................................................................... 292 WHEEL TIGHTENING TORQUE ................................................................ 292 BRAKES ...................................................................................................... 292 STEERING .................................................................................................. 293 HYDRAULIC SYSTEM ................................................................................ 293 VIBRATION.................................................................................................. 294 CYLINDERS ................................................................................................ 295 CAPACITIES ............................................................................................... 295 CYCLE TIMES............................................................................................. 295 BUCKETS.................................................................................................... 296 GENERAL DIMENSIONS ............................................................................ 297 STANDARD ACCESSORIES ...................................................................... 299 ALPHABETICAL INDEX ........................................................................ 300 - 302

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TO THE OWNER

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595SLE AND 595LSP LOADER BACKHOES

CP99D004

Dealer’s stamp

CASE France Rue des meuniers 60330 Le Plessis-Belleville FRANCE

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Template Name: OM_1_col Template Date: 1994_04_29

Type shown : 595 LSP (sideshift (offset) backhoe version)

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 conforms to current labour safety regulations and all national highway and road regulations. See "Official documents" on next page. However, this does not exclude all risk of accident; 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 standard attachments and equipment of this machine are intended for general earthmoving purposes and re-handling. If the machine is to be used for lifting loads (tubing, concrete pipe sections, shoring material, etc.) then make sure the machine is suitably equipped for this type of work. If this is the case, it is mandatory for the machine to be fitted with safety valves, an overload indicator, a load lifting chart corresponding to the type of machine and its attachment and a load fixing point. At the same time, you must also strictly observe current regulations.

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

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) 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 474-4 : Safety - Loader Backhoes equipped for load lifting

IMPORTANT : An original of this “EC” conformity declaration is supplied with each machine and must be kept carefully by the owner. (Only a photocopy can be supplied subsequently on request).

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Your CASE Dealer is at your disposal for any further information. He will also provide any after-sales service you may require and genuine spare parts, your guarantee of quality, match and conformity with official regulations.

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

RIGHT, LEFT, FRONT, AND REAR OF THE MACHINE 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.

Operator and seat in loader attachment position 3

1

2

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4 CS95M207

1 FRONT 2 REAR

3 RIGHT-HAND SIDE 4 LEFT-HAND SIDE

Operator and seat in backhoe attachment position

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2

1

3 CS95M206

1 FRONT 2 REAR

3 RIGHT-HAND SIDE 4 LEFT-HAND SIDE

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IDENTIFICATION NUMBERS/MACHINE COMPONENTS

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.

Special for Germany 1 3

CS99D631

CP99D005

Located on right-hand side of machine Special for Italia (with the seat in loader attachment position).

1

1

3

2 3

CS99D632

2

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

CS99D630

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

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

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Machine

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TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE

IDENTIFICATION NUMBERS/MACHINE COMPONENTS

Engine

ROPS/FOPS cab

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4

5 CK98F021

CP98F026

(4) Make and type .................................

ROPS/FOPS serial number ..................

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

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

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

Maximum machine weight ....................

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

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

Component serial numbers

In conformance with : ISO 3471/1 1996

Hydraulic pump ..................................... ..............................................................

Front drive axle (4 wheel drive)............. ..............................................................

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

Gearbox ................................................ ..............................................................

Loader attachment control valve ........... ..............................................................

Backhoe attachment control valve ........ ..............................................................

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IDENTIFICATION NUMBERS/MACHINE COMPONENTS

IDENTIFICATION OF MAIN COMPONENTS Sideshift (offset) backhoe version Template Name: OM_1_col Template Date: 1994_04_29

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7 2

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3

1

CP99D004

9 8

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13

10 12 CK99D002

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Loader bucket Loader beam Front drive axle Battery box Rear axle Operator’s compartment Engine bonnet Backhoe boom Backhoe dipper or extendable dipper Backhoe bucket Backhoe attachment sideshift carriage Stabilizers Fuel tank

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IDENTIFICATION NUMBERS/MACHINE COMPONENTS

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IDENTIFICATION NUMBERS/MACHINE COMPONENTS

Centremount (axial) backhoe version Template Name: OM_1_col Template Date: 1994_04_29

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7 2

5

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3 CD99E017

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8

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10 CD99E018

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Loader bucket Loader beam Front drive axle Battery box Rear axle Operator’s compartment Engine bonnet Backhoe boom Backhoe dipper or extendable dipper Backhoe bucket Stabilizers Fuel tank

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1 2 3 4 5 6 7 8 9 10 11 12

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IDENTIFICATION NUMBERS/MACHINE COMPONENTS

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SAFETY/DECALS/HAND SIGNALS

SAFETY INSTRUCTIONS Template Name: OM_1_col Template Date: 1994_04_29

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.

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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Whatever type of work is concerned (earth moving, 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.

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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SAFETY/DECALS/HAND SIGNALS

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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.

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

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

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Make sure the doors and the engine bonnet are correctly fastened before undertaking any travel.

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

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The operator should be the only person 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 side is to be used only in case of emergency.

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

• •

Be prepared 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 serviced 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 structure (ROPS) which ensures your safety. The seat belt will protect you efficiently 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.

Make sure you know ways of getting out of the machine (emergency exit via the right-hand side) in case the machine falls over or if access via the left-hand side is not possible. Make sure that the right-hand door is not locked.

Check the condition and pressure of the tyres regularly.

The integrity of the vehicle electrical installation is paramount to the machines performance, hence in no uncertain terms should the electrical system be modified without written consent from CASE engineering.

Fitment of any auxiliary loads is restricted to the available power sockets only.

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Template Name: OM_1_col Template Date: 1994_04_29

the instructions and warnings given in this manual before operating the machine.

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On road and job site • Read and ensure that you understand •

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BEFORE USING THE MACHINE

SAFETY/DECALS/HAND SIGNALS

Road operation • Check that both the Template Name: OM_1_col Template Date: 1994_04_29

cab doors are closed correctly before undertaking any road travel.

•

On the job site • Operating the machine

requires your full attention. Caution on the part of the operator can prevent accidents. Make sure you know the capabilities and limits of the machine and the space needed for it to operate. There are areas of poor visibility in the machine’s working range. Have someone guide you for all jobs which have poor visibility.

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

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•

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•

Check all around the machine every day to ensure there are no oil leaks or hydraulic fluid leaks.

Tighten connections as necessary and replace any parts as required.

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.

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.

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SAFETY/DECALS/HAND SIGNALS

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• • • •

•

Never operate any of the machine’s controls unless you are seated correctly in the operator’s seat.

•

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

•

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

Stop the engine, engage parking brake and remove the starter switch key even for stops of short duration.

•

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 wheel chock to immobilize the machine (specific to certain countries).

Never travel at full speed with the loader attachment completely raised.

Never travel at high speed if the loader bucket hinders visibility. You could drive into a hidden object.

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

When entering or leaving the operator's compartment, it is essential that the loader 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.

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machine. A passenger can fall or cause an accident.

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On road and job site • Do not allow anyone to climb onto the •

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OPERATING THE MACHINE

SAFETY/DECALS/HAND SIGNALS

On the job site • On job sites on the public highway, use • Template Name: OM_1_col Template Date: 1994_04_29

•

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•

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•

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regulation signals, taking into account the working range of the machine.

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

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Avoid running the engine in an enclosed space. If it cannot be avoided, ensure good ventilation under all circumstances.

•

Do not work close to live overhead electric lines without first making sure that the minimum distances are observed : - Under 57,000 volts : 3 meters (118 inch).

- Over 57,000 volts : 5 meters (197 inch).

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.

Do not allow anyone to stand in the machine working area. If the operator uses the swing or attachment controls wrongly, this could cause an accident.

Stop all movement until the person has moved away.

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•

Before moving the stabilizers make sure that no person is within the working range of the stabilizers.

When moving the machine onto a trailer, place the gear change lever in first gear. Keep the loader bucket 20 cm (8 inch) from the ground.

•

Load lifting must be carried out in accordance with the instructions shown in this manual and in accordance with current regulations.

Before using the backhoe attachment make sure that the machine is clear of the ground by means of the stabilizers and the loader attachment.

Any uncontrolled movement of the machine can cause an accident.

Before turning the operator’s seat to the backhoe attachment working position, it is essential to place the direction of travel control lever and the gear change lever in the neutral position and to immobilize the machine by means of the parking brake lever.

If you are using the backhoe attachment or if you are carrying out maintenance operations, use the engine throttle lever. The use of the lever for any other operations can cause accidents.

In case of any operational problem or damage, move the machine to a place of safety, lower the loader attachment and the backhoe attachment to the ground, stop the engine, engage parking brake, and remove the starter switch key. Find the cause of the defect or inform responsible personnel. Take measures 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.

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SAFETY/DECALS/HAND SIGNALS

•

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

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

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

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

2. Lower the loader bucket until it is pressing on the ground.

9. Lock the loader attachment controls.

3. Place the backhoe attachment in the road travel position.

4. Place the direction of travel and speed change levers in the neutral position.

5. Immobilize the machine by means of the parking brake.

10.Make sure that the windows and the engine bonnet are correctly fastened and lock the operator’s compartment doors.

11.Check that no part of the machine is protruding onto the public highway. If this cannot be avoided, install signs in accordance with regulations.

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6. Raise the stabilizers completely.

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PARKING THE MACHINE

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SAFETY/DECALS/HAND SIGNALS

• Template Name: OM_1_col Template Date: 1994_04_29

• • •

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•

MAINTENANCE AND ADJUSTMENTS carry out any maintenance • If the attachment is raised

Do not operations until you have read and understood the instructions and warnings given in this manual.

or the machine moves when there is no operator, serious injury can result.

Before carrying out any maintenance on this machine, proceed in the following manner :

Wear suitable clothing when servicing the machine.

When servicing the machine, place a “Do not start up” label on the instrument panel.

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 injury.

If you do not understand a maintenance or adjustment procedure, consult your CASE Dealer.

1. Park the machine on flat, level ground.

2. Lower the loader and backhoe attachments until they are resting on the ground.

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

4. Engage the parking brake.

5. Lock the loader attachment controls.

6. Block the wheels to prevent any machine movement.

If a servicing operation requires the loader attachment to be raised (working on the engine), install the loader attachment support strut.

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Unauthorized modifications of the machine can cause serious injuries.

Do not carry out any modification on this machine without obtaining prior authorization from your CASE Dealer.

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

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•

•

•

Some of the machine’s components are subject to type approvals. It is mandatory when replacing those components 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 injury. Take the necessary safety precautions (protective clothing and face and hand protection) to prevent all such risks. In addition, before handling these products, read the manufacturer’s specific instructions for their use. If hydraulic fluid penetrates the skin a doctor must be called immediately.

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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.

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

Take the necessary safety measures to protect your face when using compressed air.

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 invalidated.

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.

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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Template Name: OM_1_col Template Date: 1994_04_29

•

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

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•

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SAFETY/DECALS/HAND SIGNALS

SAFETY/DECALS/HAND SIGNALS

Template Name: OM_1_col Template Date: 1994_04_29

PREVENTION OF FIRE OR EXPLOSIONS • Engine fuel can cause an explosion or • The electrical a fire.

- Never re-fuel when the engine is running.

- Do not smoke during re-fuelling.

- Take all the necessary safety measures when welding, grinding or when working near a naked flame.

• •

system or the engine exhaust may produce sparks. Before using the machine in an area which may contain inflammable vapours, ensure that there is good ventilation.

•

Use a non-inflammable product for cleaning parts.

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A spark or flame can cause the hydrogen in a battery to explode. To prevent any risk of explosion, observe the following instructions : - Remove the battery master switch key (optional).

- When disconnecting the battery cables, always disconnect the negative (-) cable first.

- To reconnect the battery cables, always connect the negative (-) cable last.

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

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

• •

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.

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SAFETY/DECALS/HAND SIGNALS

• •

•

•

•

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.

Do not try to weld or ROPS/FOPS cab.

Batteries produce explosive gases.

Keep all flames, sparks and cigarettes away. Provide good ventilation when changing a battery or using a battery in an enclosed space. Always protect your eyes when working near a battery.

Boiling coolant solution can spray out if the radiator cap is removed while the system is still hot. To remove the cap : allow the system to cool down, turn the cap to the first notch and wait until there is no more pressure. Then remove the cap.

ROPS/FOPS CAB straighten the • Do not install

Do not modify the ROPS/FOPS cab 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 if subjected to roll over or damage. Do not attempt to repair it.

If you operate this machine without a ROPS/FOPS cab 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 removed.

accessories (fixed or otherwise) which can increase the weight of the machine. This could cause serious accidents. Do not exceed the maximum weight shown on the ROPS/FOPS cab (identification plate).

•

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

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Template Name: OM_1_col Template Date: 1994_04_29

•

Battery electrolyte causes severe burns. The battery contains sulphuric acid. Avoid any contact with the skin, 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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•

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PREVENTION OF BURNS

SAFETY/DECALS/HAND SIGNALS

RIDE CONTROL SYSTEM (optional) • Never operate the ride control system • Never use the ride control

system during precise levelling operations or when using the backhoe attachment.

Template Name: OM_1_col Template Date: 1994_04_29

when the machine is raised off the ground by means of the loader beams and the loader bucket. The machine could fall to the ground and cause serious or fatal injury.

•

If the ride control system is operated when the starter switch key is in the “ON” position, the loader beams may rise or lower slightly due to the effect of the hydraulic accumulator.

RIDE CONTROL SYSTEM ACCUMULATOR (optional) • Release pressure completely in the • Completely release pressure TRIM THIS EDGE

in the accumulator before attempting to disassemble the accumulator.

hydraulic system before disconnecting hydraulic piping or hoses. Hydraulic oil squirting under pressure can cause serious injury.

•

•

Use only dry inert gas to pre-load the accumulator, such as pure nitrogen.

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If the accumulator does not function correctly, replace the accumulator.

Never try to carry out any servicing operation on the accumulator to avoid replacing it. If these instructions are not followed, serious or fatal injury can result.

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SAFETY/DECALS/HAND SIGNALS

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

!

WARNING : Make sure that all decals are perfectly legible. Clean them regularly, 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 at the bottom of the decal.

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 it is placed in its correct location.

Keep away from the machine

CS98H500

CP99D006

Part number : 6101949M1

CD98K018

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Template Name: OM_1_col Template Date: 1994_04_29

!

Alt= to hide template information Alt+ to display template information

DECALS

SAFETY/DECALS/HAND SIGNALS

External noise level

Internal noise level

Template Name: OM_1_col Template Date: 1994_04_29

CP99D007

CP99D007

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CS98G597

CS98G598

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Part number : 3508878M1 This decal shows the value in decibels of the external noise level of the machine, as guaranteed by the manufacturer. As per european directive 86/662/EEC.

Part number : 3508887M1 This decal shows the value in decibels of the internal noise level in the operator’s compartment, as guaranteed by the manufacturer. As per european directive 86/662/EEC.

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SAFETY/DECALS/HAND SIGNALS

Filling the fuel tank

CK98F022

CS98G575

CS98C062

Part number : 3517221M2 This decal shows the location of the fuel tank filler orifice.

Template Name: OM_1_col Template Date: 1994_04_29

Part number : 3216714

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CD98F013

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Battery

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SAFETY/DECALS/HAND SIGNALS

Filling the hydraulic reservoir

Instructions for use of the backhoe attachment

Template Name: OM_1_col Template Date: 1994_04_29

CK98F023

CK98K007

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CS98C210

CS98J526

Part number : 3517222M2 This decal shows the location of the hydraulic reservoir filler orifice.

Part number : 3216958

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SAFETY/DECALS/HAND SIGNALS

Swinging the backhoe attachment

CD98F037

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CD99D021

CS98G508

Part number : 3216046

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Load handling

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Template Name: OM_1_col Template Date: 1994_04_29

CS98G581

Part number : 6102056M1 This decal shows that the operator must not permit any person to remain within the working area of the backhoe attachment.

SAFETY/DECALS/HAND SIGNALS

Radiator cap

Fan

Template Name: OM_1_col Template Date: 1994_04_29

CK98G014

CK98G015

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CS96C179

CS98B065

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Part number : 6010161M1 This decal shows that the radiator should never be touched nor should the radiator cap be removed while the cooling system is still hot.

Part number : 6010160M1 This decal shows that no operation should be carried on the fan or the fan belt while the engine is running.

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SAFETY/DECALS/HAND SIGNALS

CD99D022

CS96D162

CS98C063

Part number : 3517703M1 This decal shows the lifting points to be used when lifting the machine. Never use any other lifting points than those shown on this decal. See "Lifting the machine" in the "Operating instructions" section.

Part number : 3517702M1 This decal shows the tie-down points to be used when transporting the machine.

Never use any other tie-down points than those shown on this decal. See “Transporting the machine”, in the “Operating instructions” section.

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CD99D022

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Tie-down points

Template Name: OM_1_col Template Date: 1994_04_29

Lifting points

SAFETY/DECALS/HAND SIGNALS

Use of the Operator’s Manual

Controls for loader attachment

Template Name: OM_1_col Template Date: 1994_04_29

1 CK98K007

CP99D008

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2

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CD98K019

CS99E511

Part number : 6101875M1 This decal shows the operation of loader attachment control.

CS96D164

(1) Part number : 6010245M1 (2) Part number : 6010244M1 There decals show that it is mandatory to read the Operator’s Manual before using the machine.

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SAFETY/DECALS/HAND SIGNALS

CS98J546

Part number : 6100642M1 This decal shows the operation of backhoe attachment controls.

CP98F024

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European Community only

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Non-European Community

Backhoe attachment controls

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Template Name: OM_1_col Template Date: 1994_04_29

CS98J544

Part number : 6100643M1 This decal shows the operation of backhoe attachment controls.

SAFETY/DECALS/HAND SIGNALS

Extendable dipper (if equipped) Template Name: OM_1_col Template Date: 1994_04_29

Stabilizer controls (sideshift (offset) backhoe version)

CK98K001 CP98F024

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CS98J545

Part number : 6101865M1 This decal shows that the front of the pedal must be pressed to extend the extendable dipper or the rear of the pedal to retract the extendable dipper.

CS98H501

Part number : 6101923M1

CS98H502

Part number : 6101924M1 There decals show the operation of stabilizer levers.

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SAFETY/DECALS/HAND SIGNALS

Differential lock

CK99D004

CS98G578

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CK99D003

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Stabilizer controls (centremount (axial) backhoe version)

CS98H503

Part number : 6101925M1

CS98H504

Part number : 6101926M1 There decals show the operation of stabilizer levers.

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Template Name: OM_1_col Template Date: 1994_04_29

Part number : 6101927M1 This decal shows the operation of differential locking pedal.

SAFETY/DECALS/HAND SIGNALS

Backhoe attachment boom lock Template Name: OM_1_col Template Date: 1994_04_29

Maximum speed (specific to certain countries)

CK98F035 CD98K006

Part number : 3509154M1

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CS98G579

Part number : 6101928M1 This decal shows the operation of transport locking lever.

CS98G594

Part number : 3509138M1 This decal shows the maximum speed authorized on the road.

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SAFETY/DECALS/HAND SIGNALS

Filling the engine coolant

CK98J002

CS98G592

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CD98K007

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Operating instructions (specific to certain countries)

Part number : 3517219M2 This decal shows the location of the engine coolant filler orifice.

CS98G596

Template Name: OM_1_col Template Date: 1994_04_29

Part number : 3516760M1

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SAFETY/DECALS/HAND SIGNALS

Brake fluid filler orifice

Filling the engine oil

Template Name: OM_1_col Template Date: 1994_04_29

CD99D023

CK98G015

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CS98D102

CS98D100

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Part number : 3517225M2 This decal shows the location of the brake fluid reservoir.

Part number : 3517224M2 This decal shows the location of the engine oil filler orifice.

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SAFETY/DECALS/HAND SIGNALS

Start engine

CK98G015

CS98D101

CS98G586

Part number : 6101951M1 This decal warns that it is forbidden to start the engine by any other means than with the starter switch key.

Template Name: OM_1_col Template Date: 1994_04_29

Part number : 3517223M1 This decal shows the location of the transmission filler orifice.

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CD98F039

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Transmission filler orifice

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SAFETY/DECALS/HAND SIGNALS

Exhaust

Ride control system (optional)

Template Name: OM_1_col Template Date: 1994_04_29

CD99D011 CK98K007

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CS98G599

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Part number : 3517593M1 This decal shows that the exhaust pipe should not be touched while it is still hot.

CS98J537

Part number : 255927A1

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SAFETY/DECALS/HAND SIGNALS

Use the support strut

CK98D005

CS98B070

CS98G590

Part number : 6101950M1 This decal shows that it is mandatory to use the safety strut when working in the loader attachment area.

Template Name: OM_1_col Template Date: 1994_04_29

Part number : 3512683M1

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CP98F027

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Close window

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SAFETY/DECALS/HAND SIGNALS

Direction of travel

Open rear window

Template Name: OM_1_col Template Date: 1994_04_29

CD98F031

CP98F026

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CS98G591

CS98J534

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Part number : 6101914M1 This decal shows the operation of direction of travel lever.

Part number : 3511487M2

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SAFETY/DECALS/HAND SIGNALS

Load handling forbidden

CP98A029

CS98J535

CS99E509

Part number : 3216849 This decal warns that it is forbidden to attempt to lift loads by attaching them to the backhoe bucket connecting rod.

Template Name: OM_1_col Template Date: 1994_04_29

Part number : 3511488M2

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CP98F024

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Close rear window

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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 the engine

Stop the engine

PDE0002A

PDE0002

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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 bucket

Lower load or bucket

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

Raise load or bucket slowly

Lower load or bucket slowly

Template Name: OM_1_col Template Date: 1994_04_29

PDE0007A

PDE0007

Turn machine left

Turn machine right

TRIM THIS EDGE PDE0008A

PDE0008

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

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

Roll back loader bucket

Dump loader bucket

PDE0009A

PDE0009

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SAFETY/DECALS/HAND SIGNALS

Lower backhoe boom

PDE0010A

PDE0010

Backhoe dipper out

PDE0011A

PDE0011

Backhoe bucket dump

PDE0012A

PDE0012

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Template Name: OM_1_col Template Date: 1994_04_29

Backhoe bucket dig

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Backhoe dipper in

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Raise backhoe boom

SAFETY/DECALS/HAND SIGNALS

Template Name: OM_1_col Template Date: 1994_04_29

Retract extendable dipper (if equipped)

Extend extendable dipper (if equipped)

CS95M208

CS95M209

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51

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RIGHT PAGE

Template Name: OM_1_col Template Date: 1994_04_29

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CONTROLS/INSTRUMENTS/ACCESSORIES

CAB DOORS Template Name: OM_1_col Template Date: 1994_04_29

2

1 CP98F019

CP98F020

The doors are opened with the handle (1) from the outside and with the handle (2) from the inside.

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!

WARNING : Make sure that the doors are correctly closed before any travel.

NOTE : To lock the doors, use the key.

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CONTROLS/INSTRUMENTS/ACCESSORIES

IMPORTANT : Use the left-hand side for entering or leaving the operator’s compartment. The right-hand side is only for use in emergency.

!

WARNING : Never use the steering wheel or the control levers to help yourself entering or leaving the operator’s compartment.

!

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

!

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

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

CP99E002

Use the steps and access handles when entering or leaving the operator’s compartment.

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STEPS AND ACCESS HANDLES

CONTROLS/INSTRUMENTS/ACCESSORIES

INSTRUMENT PANEL Front control panel Template Name: OM_1_col Template Date: 1994_04_29

9

1

10

2 3 8 4

7

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6

5

11

12

CS98G564

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1. LOW PRESSURE IN BRAKE SERVO SYSTEM WARNING LAMP - This warning lamp comes on when the pressure in brake servo system is too low. If the lamp comes on when the machine is working, move the machine to a place of safety, stop the engine immediately, engage parking brake, remove the starter switch key and find the cause of the problem.

2. PARKING BRAKE INDICATOR LAMP - This indicator lamp comes on when the parking brake lever is engaged (wheels braked). See “Parking brake lever”.

3. MAIN BEAM INDICATOR LAMP - This indicator lamp comes on when head lights are on main beam.

4. DIRECTION OF TRAVEL LEVER INDICATOR LAMP - This indicator lamp comes on when the direction of travel lever is in neutral position.

5.

Not used.

6. ENGINE FAULT WARNING LAMP - This warning lamp comes on when an engine fault occurs. If the lamp comes on when the machine is working, move the machine to a place of safety, stop the engine, engage parking brake, remove the starter switch key and find the cause of the problem.

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CONTROLS/INSTRUMENTS/ACCESSORIES

8. DIRECTION INDICATOR LAMP - This indicator lamp flashes when the direction indicator lever is moved.

NOTE : The lamp flashes at the same speed as the indicators. If the lamp flashes at a different speed from that of the direction indicators the bulb of one of the direction indicators is defective and must be replaced. See “Replacing a bulb” in the “Electrical system” section.

9.

Not used.

10. SPEEDOMETER (optional) - The speedometer shows the forward machine speed. The big number at the top are the Km/h and the ones at the bottom are in mph.

Template Name: OM_1_col Template Date: 1994_04_29

12. SIDE LIGHT INDICATOR LAMP - This indicator lamp comes on when the side position light comes on.

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11. HOURMETER - The hourmeter shows the hours for which the engine has been operated. It also enables servicing operations to be scheduled. See “Servicing intervals” section.

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7. LOADER BUCKET ON FLOAT MODE INDICATOR LAMP - This indicator lamp comes on when the loader bucket is on float mode.

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CONTROLS/INSTRUMENTS/ACCESSORIES

Side control panel Template Name: OM_1_col Template Date: 1994_04_29

10 11 1 9

2 3 4

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8 12 5

6

7

13 CS98G565

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1. ENGINE COOLANT TEMPERATURE WARNING LAMP - This warning lamp comes on when the engine cooling system reaches an abnormally high temperature.

If the lamp comes on when the machine is working, move the machine to a place of safety, stop the engine, engage parking brake, remove the starter switch key and find the cause of the problem.

2. ALTERNATOR CHARGE WARNING LAMP - This warning lamp comes on when the alternator/fan belt is broken or when the alternator is not charging the battery. If the lamp comes on when the machine is working, move the machine to a place of safety, stop the engine, engage parking brake, remove the starter switch key and find the cause of the problem.

3. AIR FILTER RESTRICTION WARNING LAMP - This warning lamp comes on when the air filter primary element needs to be cleaned or replaced. See “Air filter” in the “Lubrication/Filters/Fluids” section.

4.

Not used.

5.

Not used.

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Not used.

7.

Not used.

8. HYDRAULIC FILTER RESTRICTION WARNING LAMP - This warning lamp comes on when the hydraulic filter needs to be replaced. See “Hydraulic system” in the “Lubrication/Filters/Fluids” section.

9. TRANSMISSION OIL TEMPERATURE WARNING LAMP - This warning lamp comes on when the transmission oil temperature is too high. If the warning lamp comes on when the machine is working, move the machine to a place of safety, stop the engine, engage parking brake, remove the starter key and find the cause of the problem.

10. ENGINE OIL PRESSURE WARNING LAMP - This warning lamp comes on when the engine oil pressure is too low. If the lamp comes on when the machine is working, move the machine to a place of safety, stop the engine, engage parking brake, remove the starter switch key and find the cause of the problem.

12. FUEL LEVEL GAUGE - This gauge shows the quantity of fuel in the fuel tank.

13. ENGINE COOLANT TEMPERATURE GAUGE - This gauge shows the temperature of the engine coolant. When the temperature is normal the needle is in the white area. If the needle is in the red area, move the machine to a place of safety, stop the engine, engage parking brake, remove the starter switch key and check the engine coolant level. Make sure that the radiator and oil cooler are perfectly clean and that all the thermostats function correctly. See “Cooling system” in the “Lubrication/ Filters/Fluids” section and “Radiator and oil cooler” in the “Maintenance/Adjustments” section.

NOTE : When the starter switch key is in the “On” position the warning lamps (2) and (10) come on. If one or more do not come on, the bulbs must be replaced.

See “Replacing a bulb” in the “Electrical system” section.

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11. ENGINE TACHOMETER - The tachometer shows the engine speed in revolutions per minute. The figures indicated must be multiplied by 100.

Template Name: OM_1_col Template Date: 1994_04_29

6.

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CONTROLS/INSTRUMENTS/ACCESSORIES

CONTROLS/INSTRUMENTS/ACCESSORIES

OPERATOR’S COMPARTMENT CONTROLS Template Name: OM_1_col Template Date: 1994_04_29

!

WARNING : Before starting the engine, make sure you are fully aware of the location and the function of each control. Operating the controls wrongly can cause serious physical injury.

Starter switch

Emergency cut-out button

0

1 2 3

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CP99D009

CP99D009

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Located on the right of the operator’s seat (with seat in loader attachment position), this switch has four positions :

Located on the side control panel, this red button can be used to enable or cancel all hydraulic functions.

Key position : Position (0) : Off. Position (1) : On. Position (2) : Pre-heat.

Position (3) : Start.

Press the button to cancel all hydraulic functions.

Turn and then raise the button for all hydraulic functions to be enabled.

NOTE : See "Starting the engine" in the "Operating instructions" section.

IMPORTANT : If a problem occurs while the hydraulic controls are being used, press the button immediately.

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LEFT PAGE

CONTROLS/INSTRUMENTS/ACCESSORIES

Direction of travel control lever

IMPORTANT : Before using the backhoe attachment controls, make sure that the lever is in neutral position (0).

0

2

CP99D002

Located to the left of the steering wheel, this lever has three positions to select the direction of travel of the machine.

Position (0) : Neutral.

In this position the machine cannot travel.

Position (1) : Forward.

Raise and push the lever completely forward. In this position, the machine can travel forwards.

Position (2) : Reverse.

Raise and pull the lever completely backwards. In this position the machine can travel in reverse and the audible warning device sounds.

NOTE : If the lever is operated in forward or reverse travel while the parking brake is engaged (wheels braked), the audible warning device will sound. The parking brake lever must be released. See "Parking brake lever".

!

WARNING : Any uncontrolled movement of the machine can cause an accident. Before turning the operator’s seat to the backhoe equipment working position, it is essential for the direction of travel lever and the gear change lever to be placed in the neutral position and the parking brake engaged.

NOTE : If the gear change lever is in the neutral position, the machine cannot move forward or in reverse. See "Gear change lever".

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1

Template Name: OM_1_col Template Date: 1994_04_29

IMPORTANT : Before stopping or starting the engine make sure that the lever is in the neutral position (0).

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

CONTROLS/INSTRUMENTS/ACCESSORIES

Template Name: OM_1_col Template Date: 1994_04_29

Gear change lever and transmission dump button

Before changing gear, press and hold the transmission dump button (B) located on the left-hand side of the lever. After changing the gear, release the button (B) to engage the clutch.

NOTE : Reduce engine speed before changing to a lower gear.

3 1

0

IMPORTANT : Before stopping or starting the engine, make sure that the lever is in the neutral position (0).

4 2

IMPORTANT : Before using the backhoe attachment controls, make sure that the lever is in neutral position (0).

B A CP99E003

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Located to the right of the steering wheel, the lever (A) enables four forward and four reverse gears to be selected. See “Transmission” in the “Specifications” section : Position (0) : Neutral.

Position (1) : First gear.

Position (2) : Second gear.

Position (3) : Third gear.

Position (4) : Fourth gear.

!

WARNING : Any uncontrolled movement of the machine can cause an accident. Before turning the operator's seat to the backhoe attachment working position, it is essential for the direction of travel lever and the gear change lever to be placed in the neutral position and the parking brake engaged.

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NOTE : (Specific to certain countries), position (4), fourth gear, does not exist since speed is limited to 20 Kph on public highways.

NOTE : (Specific to certain countries), fourth gear in reverse does not exist.

NOTE : Forward and reverse travel depends on the position of the direction of travel control lever. See "Direction of travel control lever”.

All four gears are synchronized. All the ratios can be selected without stopping the machine.

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CONTROLS/INSTRUMENTS/ACCESSORIES

2 1

3 6

1

0 5

CP99D009

CD98F032

Located to the right of the steering wheel, this lever has eight positions.

Position (0) : The lever is in a neutral position.

Position (1) : Rotate switch 90° towards operator, the side lights come on and the indicator lamp on the front control panel come on.

Position (2) : Rotate a further 90°, the lights and dipped headlights come on.

Position (3) : Pull towards operator, the main beam comes on and the indicator lamp on the front control panel comes on.

Pull again to turn main beam off.

Position (4) : With the switch in positions (0) and (1), pull towards operator to flash main beam.

Position (5) : Push the end of the lever to operate the horn.

Position (6) : Pull lever down to operate the right direction indicators and the indicator lamp on the front control panel come on.

Position (7) : Push lever up to operate the left direction indicators and the indicator lamp on the front control panel come on.

Located on the side control panel, press the switch, all the direction indicators flash simultaneously and the indicator lamp (1) comes on.

Press again the switch, all the direction indicators go out.

Sunvisor (optional)

CD98F069

Attached to the cab roof, the sunvisor can easily be positioned as required.

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4

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7

Hazard warning switch

Template Name: OM_1_col Template Date: 1994_04_29

Direction indicator lever, horn and lighting switch

CONTROLS/INSTRUMENTS/ACCESSORIES

Storage compartment

Steering column tilting lever

Template Name: OM_1_col Template Date: 1994_04_29

CK99E001 CK99D004

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Located under the steering column, this lever enables the steering column to be tilted forwards and backwards as required by the operator. Raise the lever, place the steering column in the desired position and release the lever.

IMPORTANT : It is essential that the machine to be brought to a complete halt before attempting to adjust the steering column tilt position. If this instruction is not observed an accident may occur.

CP99D002

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Cab interior light

CP99D003

Located on the roof lining, this light is controlled by a switch incorporated in the lamp base.

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CONTROLS/INSTRUMENTS/ACCESSORIES

Engine accelerator pedal

Storage areas

CK99E001

First aid kit and documentation pack storage compartment

NOTE : This pedal is coupled with the engine throttle lever. Before using the pedal, make sure that the throttle lever is in the minimum speed position. See "Engine throttle lever".

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CK99D004

Located under the steering wheel, this pedal enables the engine speed to be increased or decreased.

Maximum speed : press the pedal fully down.

Idle speed : release the pedal.

This pedal is used for travel and for operating the loader attachment.

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NOTE : To replace a cab interior light bulb, see "Replacing a bulb" in the "Electrical system" section.

CP98F023

Located on the left-hand side of the cab, this storage compartment is intended to contain a first aid kit and the documentation pack.

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Template Name: OM_1_col Template Date: 1994_04_29

IMPORTANT : Never use this pedal when working with the backhoe attachment.

CONTROLS/INSTRUMENTS/ACCESSORIES

Brake pedal

Differential locking pedal

Template Name: OM_1_col Template Date: 1994_04_29

CK99D004

CK99D004

Located under the steering wheel, this pedal operates the machine’s brakes.

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NOTE : When braking, 4-wheel drive automatically engages and stays engaged until the brakes are released.

NOTE : Check the correct braking of the machine regularly. See "Brake check" in the "Maintenance/ Adjustments" section.

Located under the steering wheel, this pedal enables equal power to be transmitted to both rear wheels. See "Differential locking" in the "Operating instructions" section.

IMPORTANT : This pedal should never be used during travel on a public highway.

IMPORTANT : Do not engage the differential when 4 wheel steering or crab steering have been selected

Parking brake lever

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CK99E002

Located on the right of the operator's seat (with the seat in the loader attachment position), this lever enables the machine to be parked securely.

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CONTROLS/INSTRUMENTS/ACCESSORIES

IMPORTANT : Never try to move the machine when the parking brake is engaged.

IMPORTANT : Before stopping the engine make sure the parking brake is engaged.

IMPORTANT : Before using the backhoe attachment controls, make sure that the parking brake is engaged.

!

WARNING : Any uncontrolled movement of the machine can cause an accident. Before turning the operator's seat to the backhoe equipment working position, it is essential for the direction of travel lever and the gear change lever to be placed in the neutral position and the parking brake engaged.

1

CP99D009

Located on the side control panel : press the switch, the two front outer worklamps and the indicator lamp (1) come on.

Press and hold the switch down a few seconds and all four worklamps come on.

Press the switch again and the two inner worklamps go out. Press the switch once more and all worklamps and the indicator lamp (1) goes out.

NOTE : To replace front working light bulbs, see "Replacing a bulb" in the "Electrical system" section.

IMPORTANT : The parking brake can also be used as an emergency brake in the event of a main brake system failure.

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Template Name: OM_1_col Template Date: 1994_04_29

IMPORTANT : When the parking brake is engaged, the audible warning device sounds if the direction of travel control lever is not in the neutral position. See "Direction of travel control lever”.

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Front working lights switch

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Raise the lever to engage the parking brake. In this position, the indicator lamp lights up on the front control panel. Lower the lever to free the machine (wheel brakes released). In this position, the indicator lamp on the front control panel goes out.

CONTROLS/INSTRUMENTS/ACCESSORIES

Rear working lights switch

Front drive axle engagement switch

Template Name: OM_1_col Template Date: 1994_04_29

1 1

CP99D009

CP98F014

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Located on the side control panel : press the switch, the two rear outer worklamps and the indicator lamp (1) come on.

Press and hold the switch down a few seconds and all four worklamps come on.

Press the switch again and the two inner worklamps go out. Press the switch once more and all worklamps and the indicator lamp (1) goes out.

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NOTE : To replace a rear working light bulb, see "Replacing a bulb" in the "Electrical system" section.

Located on the right of the steering wheel, this switch enables four wheel drive to be engaged or disengaged.

Press the switch, the front drive axle is engaged and the indicator lamp (1) comes on. Press the switch again, the front drive axle is disengaged.

NOTE : If the four wheel drive does not engage, move the machine slightly forward, stop the machine and then operate this switch again.

IMPORTANT : When the front drive axle is engaged, only use first or second gear.

Disengage the front drive axle before working on hard ground or using third or fourth gear.

IMPORTANT : All road travel must be undertaken with the front drive axle in disengaged position.

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CONTROLS/INSTRUMENTS/ACCESSORIES

2

1

1

CK99E002

Located under the side control panel.

This lever enables the engine speed to be increased or decreased.

Position (1) : Idle speed.

Position (2) : Maximum speed.

NOTE : To install the rotating beacons, see "Rotating beacons".

Front windshield wiper control

NOTE : To replace a rotating beacon bulb, see "Replacing a bulb" in the "Electrical system" section.

Horn switch (backhoe attachment)

1 CP98F014

Located on the right of the steering wheel. Press the switch to operates the front windshield wiper and the indicator lamp (1) comes on. Press the switch again and the front windshield wiper will stop.

CP99D009

Located on the side control panel. This momentary action switch operates the horn. The switch is to be used when working with the backhoe attachment.

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CP99D009

Located on the side control panel : Press the switch, the two rotating beacons and the indicator lamp (1) come on. Press the switch again and the two rotating beacons go out.

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Engine throttle lever

Template Name: OM_1_col Template Date: 1994_04_29

Rotating beacons switch

CONTROLS/INSTRUMENTS/ACCESSORIES

Front windshield washer control

Rear windshield wiper control

Template Name: OM_1_col Template Date: 1994_04_29

1 CP98F014

CP99D009

Located on the right of the steering wheel. This momentary action switch operates the front windshield washer.

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IMPORTANT : Never operate the windshield washer switch when the windshield washer reservoir is empty, since this may cause damage to the electric pump. See "Front and rear windshield washer reservoir".

Located on the side control panel. Press the switch to operates the rear windshield wiper and the indicator lamp (1) comes on. Press the switch again and the rear windshield wiper will stop.

Rear windshield washer control

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CP99D009

Located on the side control panel. This momentary action switch operates the rear windshield washer.

IMPORTANT : Never operate the windshield washer switch when the windshield washer reservoir is empty, since this may cause damage to the electric pump. See "Front and rear windshield washer reservoir".

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NOTE : (595LSP only) with the seat facing rearwards the same procedure must be followed or each time seat position.

Backhoe attachment boom unlocking switch (centremount (axial) backhoe version)

1

Hydraulic enable switch

1 CP99D009

Located on the side control panel. Press the switch and the backhoe attachment boom is locked and the indicator lamp (1) comes on. Press the switch again and the backhoe attachment boom is unlocked.

1

CP99D009

Located on the side control panel. After starting the engine press the switch to switch on the electronic control system.

The indicator lamp (1) will glow to indicate that the loader hydraulics are active if the seat is facing forward. Press the switch again to switch off the electronic control system.

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CP99D009

Located on the side control panel. Press the switch and the indicator lamp (1) comes on. In this case the flow provides from the larger pump only. Use the low flow position for more precise control of the loader attachment and backhoe attachment also used for roading. Press the switch again to provide full flow from both pumps.

Template Name: OM_1_col Template Date: 1994_04_29

Hydraulic pumps flow control

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CONTROLS/INSTRUMENTS/ACCESSORIES

CONTROLS/INSTRUMENTS/ACCESSORIES

Template Name: OM_1_col Template Date: 1994_04_29

Backhoe attachment sideshift carriage locking and unlocking switch (sideshift (offset) backhoe version)

Loader quick attach locking/unlocking switch (optional)

1

1

CP98F014

CP99D009

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Located on the side control panel. Press the switch to unlock the sideshift carriage and the indicator lamp (1) comes on.

Press the switch again to lock the sideshift carriage.

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NOTE : For sideshift operation see “Backhoe attachment sideshift” in the “Operating instructions” section.

Located on the right of the steering wheel. Press and hold the switch, the loader quick attach is unlocked and the indicator lamp (1) comes on. Release the switch, the loader quick attach is locked.

See “Removal and installation of quick attach loader bucket” in the “Operating instructions” section.

Return to dig switch

1 CP99D009

Located on the side control panel. Press the switch to enable the return to dig function and the indicator lamp (1) comes on. Press the switch again to disable the return to dig function.

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CONTROLS/INSTRUMENTS/ACCESSORIES

Fuses and relays location

CP99E001

Located behind side console front panel.

See “Fuses and relays” in the “Electrical system” section.

CK98F035

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Radio compartment

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Backhoe attachment boom unlocking lever

CK97N041

CP98F022

Located on the roof lining, this preequipped compartment is intended for installing a 12 volt radio.

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Template Name: OM_1_col Template Date: 1994_04_29

Located to the left of the floor (with the operator’s seat in the backhoe attachment position). This lever enables the backhoe boom locking stop to be unlocked after road travel. See “Setting the backhoe attachment in the working position” in the “Operating instructions” section.

CONTROLS/INSTRUMENTS/ACCESSORIES

Cigar lighter Template Name: OM_1_col Template Date: 1994_04_29

CD99E021

Located under the side control panel.

Ashtray TRIM THIS EDGE

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CP98F023

Located on the left-hand side of the cab (with the operator’s seat in the loader attachment position).

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CONTROLS/INSTRUMENTS/ACCESSORIES

A 3 2 1 CK99E004 CK99E003

Located under the side control panel, this switch makes it possible to select 4 wheel steering, two wheel steering or crab steering. The switch has three positions :

IMPORTANT : Before undertaking any road travel, select two wheel steer position and place the tab over the switch to lock it in this position.

Template Name: OM_1_col Template Date: 1994_04_29

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Position (1) : 4 wheel steering.

Position (2) : 2 wheel steering.

Position (3) : crab steering.

The tab (A) is used to lock the switch in 2 wheel steer position.

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Steering mode switch

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CONTROLS/INSTRUMENTS/ACCESSORIES

OPERATOR’S SEAT Template Name: OM_1_col Template Date: 1994_04_29

To operate the machine correctly with maximum efficiency and comfort, the seat should be correctly adjusted to suit the height of the operator.

!

WARNING : Before using the controls, make sure that the seat is adjusted and positioned correctly.

Suspension adjustment

Forward, rear and swivel adjustment

2

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1 CK99E005

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Sit on the seat. Turn handle (1) to adjust seat height. Clockwise to raise seat. AntiClockwise to lower seat. Check ride indicator (2) shows green. If red, readjust seat height. Within the green band of the ride indicator there is 75 mm of height adjustment for any driver.

NOTE : The seat is designed so that it is unnecessary to make any adjustment for the driver weight.

CK99E005

Hold the lever to the top, slide the seat until the desired position is reached and then release the lever. To turn the seat, hold the lever to the top, slide the seat to the rear and turn it. Release the lever and make sure that the seat is correctly locked in position.

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CONTROLS/INSTRUMENTS/ACCESSORIES

CK99E007

Lumbar support adjustment

!

CK99E007

Turn the knob to obtain good back support from the seat back.

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

The machine is equipped with a roll over protection structure (ROPS) which ensures your safety. The seat belt will protect you efficiently if you attach it correctly and if you always wear it. The seat belt must not be too loose.

It must not be twisted or caught in the seat.

NOTE : (595LSP type), the seat is fitted with a microswitch which makes it impossible to use the machine if nobody is sitting in the operator’s seat.

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Sit comfortably on the seat. Pull a generous amount of belt out of the reel, and buckle it. Allow the excess belt to retract back into the reel.

Template Name: OM_1_col Template Date: 1994_04_29

CK99E006

To adjust the seat back angle, hold the lever downwards, move the seat back to obtain the desired position and then release the lever.

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Seat back angle adjustment Seat belt

CONTROLS/INSTRUMENTS/ACCESSORIES

Control lever tilt angle (595LSP type)

Handrest adjustment (595LSP type)

Template Name: OM_1_col Template Date: 1994_04_29

CK99E008

CK99E008

Hold the lever up, tilt the control lever to the required position and then release the lever.

Loosen the locking knob, slide the handrest to the required position and then tighten the locking knob.

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Control lever fore/aft adjustment (595LSP type)

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CK99E008

Loosen the locking knob, slide the control lever to the required position and then tighten the locking knob

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CONTROLS/INSTRUMENTS/ACCESSORIES

!

WARNING : Before starting the engine, make sure you are fully aware of the location and the function of each control. Operating the controls wrongly can cause serious physical injury.

!

WARNING : Before using the controls make sure that the operator’s seat is correctly adjusted in the loader attachment position.

5 2

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4 6

1

3

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LOADER ATTACHMENT CONTROLS (595SLE type)

CD99E021

Located on the right of the steering wheel, this eight position control lever operates the loader attachment functions. The speed of movement of each function depends on the tilting angle of the control lever.

NOTE : Engine rpm to be set manually with the hand throttle NOTE : A decal located to the right of the control lever explains the function of each control.

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Template Name: OM_1_col Template Date: 1994_04_29

7

CONTROLS/INSTRUMENTS/ACCESSORIES

Loader controls, neutral and hold

Filling the loader bucket

Template Name: OM_1_col Template Date: 1994_04_29

When in the neutral/hold position (0) the loader beam movement can be stopped.

As soon as the control lever is released, it automatically returns to the neutral position (0) and the loader beam remains in the position where it was when movement stopped.

3

Raising the loader beam CS98C011

1

With the control lever in position (3), the bucket rolls back (crowds).

Dumping the loader bucket TRIM THIS EDGE

4

CS98C009

With the control lever in position (1), the loader beam rises.

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Lowering the loader beam 2 CS98C012

With the control lever in position (4), the bucket dumps.

CS98C010

With the control lever in position (2), the loader beam lowers.

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Loader bucket float control

NOTE : It is possible to adjust the tilt angle for bucket dig. See “Loader bucket return-to-dig adjustment" in the "Maintenance/Adjustments" section.

5

Automatic loader bucket levelling 7

NOTE : In this position the control lever does not automatically return to neutral when it is released. It is necessary to move it manually.

CS98E516

With the control lever in position (7), the loader beam raises and simultaneously the loader bucket remains in the level position.

Loader beam automatic return to dig

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CS98C013

With the control lever in the released position (5), the bucket follows the contours of the ground without it being necessary to operate the lever.

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CONTROLS/INSTRUMENTS/ACCESSORIES

CS98C206

With the control lever in position (6), the loader beam lowers and simultaneously the loader bucket places itself in the digging position.

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Template Name: OM_1_col Template Date: 1994_04_29

6

CONTROLS/INSTRUMENTS/ACCESSORIES

Transmission dump button Template Name: OM_1_col Template Date: 1994_04_29

7 in 1 loader bucket clamshell control (if equipped)

1

2

CD99E020

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Located below the control lever, this button, when pressed and held down, gives maximum power to the loader hydraulics.

This will cause the transmission to revert to neutral. Release the transmission dump button to engage the transmission once more. See "Loader attachment operating instructions" in the "Job site and road operation" section.

CD99E021

Located on the control lever, this control is used to operate the 7 in 1 loader bucket clamshell. The speed at which the clamshell opens depends on how hard the switch is pressed.

1

2

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IMPORTANT : When the button is pressed, the machine freewheels. If necessary, use the brakes to stop the machine.

CS98C014

CS98C015

With the control lever in position (1), the clamshell opens.

With the control lever in position (2), the clamshell closes.

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CONTROLS/INSTRUMENTS/ACCESSORIES

!

WARNING : Before starting the engine, make sure you are fully aware of the location and the function of each control. Operating the controls wrongly can cause serious physical injury.

!

WARNING : Any uncontrolled movement of the machine can cause an accident. Before turning the operator’s seat to the backhoe attachment working position, it is essential to place the direction of travel control lever and the gear change lever in the neutral position, the parking brake engaged.

!

WARNING : Before using the backhoe controls, make sure that the operator’s seat is correctly adjusted in the backhoe attachment position.

NOTE : A decal located in front of levers explain the function of the controls.

IMPORTANT : Whenever the backhoe attachment is used, it is essential for the machine to be resting on the stabilizers. See "Stabilizer controls" and "Setting the machine in the backhoe attachment working position" in the "Operating instructions" section.

Template Name: OM_1_col Template Date: 1994_04_29

IMPORTANT : Two backhoe attachment control configurations exist, depending on the country concerned : (1) European Community Configuration (EC).

(2) Non-European Community Configuration (outside EC).

The operating pattern of the control levers is different. Check which configuration you have on your machine.

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Control levers are used to operate the backhoe attachment. The speed of movement of each control depends on the angle to which the lever is tilted.

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BACKHOE ATTACHMENT CONTROLS (595SLE type)

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CONTROLS/INSTRUMENTS/ACCESSORIES

European Community Configuration (EC) Template Name: OM_1_col Template Date: 1994_04_29

E A

G 0

C

0

H D F

B

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CK99E009

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Backhoe dipper and backhoe attachment swing left-hand control lever

A

This lever has five positions : Position (0) : Neutral/hold. This position enables the attachment movement to be stopped. As soon as the lever is released, it automatically returns to the neutral position (0) and the attachment remains in the position where it was when movement stopped.

B

CD99E001

Position (A) : extends.

Position (B) : retracts.

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The

backhoe

dipper

The

backhoe

dipper

This lever has five positions :

C

CD98F052

Position (C) : The backhoe attachment swings to the left.

Position (D) : The backhoe attachment swings to the right.

Position (0) : Neutral/hold. This position enables the attachment movement to be stopped. As soon as the lever is released, it automatically returns to the neutral position (0) and the attachment remains in the position where it was when movement stopped.

F

E

CD99E001

Position (E) : The backhoe boom lowers.

Position (F) : The backhoe boom rises.

G

H CD99E001

Position (G) : The backhoe bucket digs (crowds).

Position (H) : The backhoe bucket dumps.

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D

Template Name: OM_1_col Template Date: 1994_04_29

Backhoe boom and backhoe bucket righthand control lever

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CONTROLS/INSTRUMENTS/ACCESSORIES

CONTROLS/INSTRUMENTS/ACCESSORIES

Non-European Community Configuration (outside EC) Template Name: OM_1_col Template Date: 1994_04_29

E A

G 0

C

0

H D F

B

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CK99E009

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Backhoe boom and backhoe attachment swing left-hand control lever

B

This lever has five positions : Position (0) : Neutral/hold. This position enables the attachment movement to be stopped. As soon as the lever is released, it automatically returns to the neutral position (0) and the attachment remains in the position where it was when movement stopped.

A

CD99E001

Position (A) : The backhoe boom lowers.

Position (B) : The backhoe boom rises.

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G C

D

H CD98F052

CD99E001

Backhoe dipper and backhoe bucket righthand control lever

Position (G) : The backhoe bucket digs (crowds).

Position (H) : The backhoe bucket dumps.

Extendable dipper control pedal (if equipped)

This lever has five positions :

J

Position (0) : Neutral/hold. This position enables the attachment movement to be stopped. As soon as the lever is released, it automatically returns to the neutral position (0) and the attachment remains in the position where it was when movement stopped.

0

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Position (C) : The backhoe attachment swings to the left.

Position (D) : The backhoe attachment swings to the right.

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CONTROLS/INSTRUMENTS/ACCESSORIES

K

E

Position (0) : Neutral. This position enables the movement of the extendable dipper to be stopped.

F CD99E001

Position (E) : extends.

Position (F) : retracts.

The

backhoe

dipper

The

backhoe

dipper

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Template Name: OM_1_col Template Date: 1994_04_29

CP98F018

This pedal has three positions :

CONTROLS/INSTRUMENTS/ACCESSORIES

K

Template Name: OM_1_col Template Date: 1994_04_29

J CD98F070

Position (J) : The extendable dipper extends.

Position (K) : The extendable dipper retracts.

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Before using this pedal make sure that the extendable dipper is mechanically unlocked. See “Setting the backhoe attachment in the working position” in the “Operating instructions” section.

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Template Name: OM_1_col Template Date: 1994_04_29

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CONTROLS/INSTRUMENTS/ACCESSORIES

LOADER ATTACHMENT AND BACKHOE ATTACHMENT CONTROLS (595LSP type) Template Name: OM_1_col Template Date: 1994_04_29

!

WARNING : Before starting the engine, make sure you are fully aware of the location and the function of each control. Operating the controls wrongly can cause serious physical injury.

When the machine is in normal use, the functions controlled by the loader right and left control arms depend on the position of the operator’s seat. (Forward-facing position : loader attachment operation, rear-facing position : backhoe loader operation).

This being said, it is nevertheless possible to use the loader attachment controls when the seat is in rear-facing position and the backhoe attachment when the seat is in front-facing position. See "Loader attachment or backhoe attachment selection button”.

Loader attachment control lever TRIM THIS EDGE

!

WARNING : Before using the loader attachment controls, make sure the operator’s seat is correctly adjusted in loader attachment operation position.

5

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2 4 6

1

3 7

CK99E010

In "Loader Attachment" position, the right-hand lever controls all the loader functions.

The left-hand lever controls is not operational.

The speed of movement of each function depends on the tilting angle of the lever controls.

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CONTROLS/INSTRUMENTS/ACCESSORIES

Lowering the loader beam 2

Loader controls, neutral and hold When in the neutral/hold position (0) the loader beam movement can be stopped.

As soon as the control lever is released, it automatically returns to the neutral position (0) and the loader beam remains in the position where it was when movement stopped.

CS98C010

With the control lever in position (2), the loader beam lowers.

Raising the loader beam

Filling the loader bucket

1

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3

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NOTE : A decal located to the right of the control lever explains the function of each control.

CS98C009

With the control lever in position (1), the loader beam rises.

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Template Name: OM_1_col Template Date: 1994_04_29

CS98C011

With the control lever in position (3), the bucket rolls back (crowds).

CONTROLS/INSTRUMENTS/ACCESSORIES

Dumping the loader bucket

Loader beam automatic return to dig

Template Name: OM_1_col Template Date: 1994_04_29

4

6

CS98C012

CS98C206

With the control lever in position (4), the bucket dumps.

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Loader bucket float control

With the control lever in position (6), the loader beam lowers and simultaneously the loader bucket places itself in the digging position.

NOTE : It is possible to adjust the tilt angle for bucket dig. See “Loader bucket return-to-dig adjustment" in the "Maintenance/Adjustments" section.

5

Automatic loader bucket levelling

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7

CS98C013

With the control lever in the released position (5), the bucket follows the contours of the ground without it being necessary to operate the lever.

NOTE : In this position the control lever does not automatically return to neutral when it is released. It is necessary to move it manually.

CS98E516

With the control lever in position (7), the loader beam raises and simultaneously the loader bucket remains in the level position.

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1

2

CK99E011 CK99E010

Located on the control lever, this control is used to operate the 7 in 1 loader bucket clamshell. The speed at which the clamshell opens depends on how hard the switch is pressed.

1

2

IMPORTANT : When the button is pressed, the machine freewheels. If necessary, use the brakes to stop the machine.

CS98C014

CS98C015

With the control lever in position (1), the clamshell opens.

With the control lever in position (2), the clamshell closes.

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Located below the control lever, this button, when pressed and held down, gives maximum power to the loader hydraulics.

This will cause the transmission to revert to neutral. Release the transmission dump button to engage the transmission once more. See "Loader attachment operating instructions" in the "Job site and road operation" section.

Template Name: OM_1_col Template Date: 1994_04_29

7 in 1 loader bucket clamshell control (if equipped)

Transmission dump button

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CONTROLS/INSTRUMENTS/ACCESSORIES

CONTROLS/INSTRUMENTS/ACCESSORIES

Backhoe attachment controls Template Name: OM_1_col Template Date: 1994_04_29

!

WARNING : Any uncontrolled movement of the machine can cause an accident. Before turning the operator’s seat to the backhoe attachment working position, it is essential to place the direction of travel control lever and the gear change lever in the neutral position and to immobilize the machine by means of the parking brake lever.

!

WARNING : Before using the backhoe controls, make sure that the operator’s seat is correctly adjusted in the backhoe attachment position.

In "Backhoe Attachment" position, the right and left-hand control levers enable all the backhoe attachment functions to be used.

The speed of movement of each function depends on the angle to which the control levers are tilted. See "Backhoe attachment working mode selection switch".

NOTE : A decal on the rear window explains the function of each control.

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IMPORTANT : Whenever the backhoe attachment is used, it is mandatory for the machine to be resting on the stabilizers. See "Stabilizer controls" and "Setting the machine in the backhoe attachment working position" in the "Operating Instructions" Section.

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IMPORTANT : Two backhoe attachment control configurations exist, depending on the country concerned : (1) European Community Configuration (EC).

(2) Non-European Community Configuration (outside EC).

The operating pattern of the control levers is different. Check which configuration you have on your machine.

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Template Name: OM_1_col Template Date: 1994_04_29

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CONTROLS/INSTRUMENTS/ACCESSORIES

European Community Configuration (EC) Template Name: OM_1_col Template Date: 1994_04_29

E

A C

0

G

D

H

0

F

B

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CP99E004

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Backhoe dipper and backhoe attachment swing left-hand control lever

A

Position (0) : Neutral/hold. This position enables the attachment movement to be stopped. As soon as the control lever is released, it automatically returns to the neutral position (0) and the attachment remains in the position where it was when movement stopped.

B

CD99E001

Position (A) : extends.

Position (B) : retracts.

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The

backhoe

dipper

The

backhoe

dipper

D

Position (0) : Neutral/hold. This position enables the attachment movement to be stopped. As soon as the control lever is released, it automatically returns to the neutral position (0) and the attachment remains in the position where it was when movement stopped.

C

CD98F052

Position (C) : The backhoe attachment swings to the left.

Position (D) : The backhoe attachment swings to the right.

E

CD99E001

Position (E) : The backhoe boom lowers.

Position (F) : The backhoe boom rises.

G

H CD99E001

Position (G) : The backhoe bucket digs (crowds).

Position (H) : The backhoe bucket dumps.

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F

Template Name: OM_1_col Template Date: 1994_04_29

Backhoe boom and backhoe bucket righthand control lever

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CONTROLS/INSTRUMENTS/ACCESSORIES

CONTROLS/INSTRUMENTS/ACCESSORIES

Non-European Community Configuration (outside EC) Template Name: OM_1_col Template Date: 1994_04_29

E

A C

0

G

D

H

0

F

B

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CP99E004

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Backhoe boom and backhoe attachment swing left-hand control lever

B

This lever has five positions : Position (0) : Neutral/hold. This position enables the attachment movement to be stopped. As soon as the control lever is released, it automatically returns to the neutral position (0) and the attachment remains in the position where it was when movement stopped.

A

CD99E001

Position (A) : The backhoe boom lowers.

Position (B) : The backhoe boom rises.

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G C

D

H CD98F052

CD99E001

Backhoe dipper and backhoe bucket righthand control lever

Position (G) : The backhoe bucket digs (crowds).

Position (H) : The backhoe bucket dumps.

Extendable dipper control pedal (if equipped)

Position (0) : Neutral/hold. This position enables the attachment movement to be stopped. As soon as the control lever is released, it automatically returns to the neutral position (0) and the attachment remains in the position where it was when movement stopped.

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Position (C) : The backhoe attachment swings to the left.

Position (D) : The backhoe attachment swings to the right.

J

0

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CONTROLS/INSTRUMENTS/ACCESSORIES

K

E

Position (0) : Neutral. This position enables the movement of the extendable dipper to be stopped.

F CD99E001

Position (E) : extends.

Position (F) : retracts.

The

backhoe

dipper

The

backhoe

dipper

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Template Name: OM_1_col Template Date: 1994_04_29

CK99E012

This pedal has three positions :

CONTROLS/INSTRUMENTS/ACCESSORIES

K

Template Name: OM_1_col Template Date: 1994_04_29

J CD98F070

Position (J) : The extendable dipper extends.

Position (K) : The extendable dipper retracts.

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Before using this pedal make sure that the extendable dipper is mechanically unlocked. See “Setting the backhoe attachment in the working position” in the “Operating instructions” section.

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When the button is pressed again, the function controls which are operational will depend on the position of the operator’s seat.

NOTE : This button should only be used occasionally.

When in "Loader Attachment" configuration (seat facing forwards), press this button to operate the "Backhoe Attachment" function controls without having to turn the seat to the rear-facing position.

This will cause the audible alarm device to sound.

When in "Backhoe Attachment" configuration, (seat facing backwards), press this button to operate the "Loader Attachment" function controls without having to turn the seat to the front-facing position.

This will cause the audible warning device to sound.

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CK99E013

This button is located under the left-hand control lever. It enables the loader controls or the backhoe controls to be selected.

Template Name: OM_1_col Template Date: 1994_04_29

Loader or backhoe attachment selector button

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CONTROLS/INSTRUMENTS/ACCESSORIES

CONTROLS/INSTRUMENTS/ACCESSORIES

STABILIZER CONTROLS Template Name: OM_1_col Template Date: 1994_04_29

!

WARNING : Any uncontrolled movement of the machine can cause an accident. Before turning the operator’s seat to the backhoe attachment working position, it is essential to place the direction of travel control lever and the gear change lever in the neutral position, the parking brake engaged.

!

WARNING : Before using the stabilizer controls, make sure that the operator’s seat is correctly adjusted in the backhoe attachment position.

IMPORTANT : Whenever the backhoe attachment is used the machine must be resting on the stabilizers.

!

WARNING : Before moving the stabilizers make sure that no person is within the working range of the stabilizers.

NOTE : Two decals explains the function of the controls.

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N

L

0

0

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P

M

CK99E014

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Left-hand stabilizer lefthand control lever

Right-hand stabilizer right-hand control lever

This lever has three positions :

This lever has three positions :

Position (0) : Neutral. This position stops the movement of the left-hand stabilizer.

As soon as the lever is released, it automatically returns to the neutral position (0) and the left-hand stabilizer stops raising or lowering.

Position (L) : The left-hand stabilizer lowers.

Position (M) : The left-hand stabilizer rises.

Position (0) : Neutral. This position stops the movement of the right-hand stabilizer.

As soon as the lever is released, it automatically returns to the neutral position (0) and the right-hand stabilizer stops raising or lowering.

Position (N) : The right-hand stabilizer lowers.

Position (P) : The right-hand stabilizer rises.

IMPORTANT : Before machine travel or before using the loader attachment, make sure that the stabilizers are completely raised.

Template Name: OM_1_col Template Date: 1994_04_29

IMPORTANT : During road travel, the stabilizers must be completely raised.

See "Road travel" in the "Job site and road travel" section.

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NOTE : To raise or lower the stabilizers at the same time, operate the two levers simultaneously.

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CONTROLS/INSTRUMENTS/ACCESSORIES

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CONTROLS/INSTRUMENTS/ACCESSORIES

HEATING, VENTILATION AND AIR CONDITIONING (optional) CONTROLS Template Name: OM_1_col Template Date: 1994_04_29

The heating, ventilation and air conditioning (optional) controls are located on the right-hand cab upright (with the operator’s seat in the loader attachment position).

Heater control

To increase the air flow, turn the knob clockwise.

To reduce the air flow, turn the knob anticlockwise.

NOTE : The air will be hot or cold depending on the position of the heater control.

Air conditioning control (optional) TRIM THIS EDGE

CK99E015

This knob enables the air temperature to be adjusted in the operator’s compartment.

To increase the temperature, turn the knob clockwise.

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To reduce temperature, turn the knob anti-clockwise.

Fan control

CK99E015

This control is used to turn on or stop the air conditioning system.

NOTE : The air conditioning can only be switched on if the blower control is not on the stop position.

Use the heater control and the fan control to adjust the air temperature.

CK99E015

This knob enables air flow to be adjusted in the operator’s compartment.

IMPORTANT : When using the air conditioning, it is essential that all the windows of the operator’s compartment are completely closed.

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CONTROLS/INSTRUMENTS/ACCESSORIES

Air vents The flow of air can be directed by means of the knurled knob and the louvers. To close the air vents, push the louvers completely inwards.

When using air conditioning (optional) the louvers must be in the open position.

CP99D002

CP98F024 CP99D002

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Main air vents

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Defrosting vents

NOTE : To obtain maximum air flow, close the main vents.

CP98F024

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Template Name: OM_1_col Template Date: 1994_04_29

NOTE : To ensure correct operation and full efficiency of the air conditioning system, it must be used at least once a week, even for a short time.

CONTROLS/INSTRUMENTS/ACCESSORIES

Template Name: OM_1_col Template Date: 1994_04_29

CK98K003

Two re-cycling vents located in the righthand side of the cab (with the operator’s seat in the loader attachment position) are controlled by the central lever.

To obtain maximum heat or cooling, open these vents.

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NOTE : When using the machine with the windows open, close the recycling vents to avoid sucking in dust which may damage the system.

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NOTE : The cab is equipped with filter which must be cleaned regularly. See "Cab filter" in the "Maintenance/ Adjustments" section.

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CONTROLS/INSTRUMENTS/ACCESSORIES

Partial opening

CD98F074

Full opening

Rear window

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CD98F072

Lift the handle and push out and down to lock the window partially open.

Ensure the handle fully engages the striker pin, pull the window closed, then push the handle down.

Opening STEP 1

1

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OPERATOR’S COMPARTMENT WINDOWS Closing Cab door windows

1 CD98F073

From the closed position, lift the handle (1) horizontally, then swing it backwards to disengage it from the striker pin, open the window and secure it in the rubber (2).

CP98F026

Turn the handle (1) and push the window outwards, retain hold of the lower handle.

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Template Name: OM_1_col Template Date: 1994_04_29

2

CONTROLS/INSTRUMENTS/ACCESSORIES STEP 2

STEP 3

Template Name: OM_1_col Template Date: 1994_04_29

2

2 CP98F027

CP98F024

Pull the bottom handle (2) inwards and upwards and secure the handle into the roof latch.

Pull the handle (2) down to engage in the lower latch. This action will bring the top of the window hard against the seal.

Closing

STEP 4

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STEP 1

1

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CP98F026 CP98F027

Hold the window and release the roof lock by pulling it back.

Turn the handle (1) to lock the window closed.

STEP 2 Lower the window until it is hanging freely, supported by the gas struts.

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CONTROLS/INSTRUMENTS/ACCESSORIES

Make sure the rear view mirrors are correctly adjusted before driving the machine.

CD98F075

FRONT AND REAR WINDSHIELD WASHER RESERVOIR

IMPORTANT : Never operate the windshield washer switch when the reservoir is empty, since this may damage the electric pump.

IMPORTANT : Before checking the reservoir, raise the loader attachment fully and install the support strut, see "Loader attachment support strut".

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

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REAR VIEW MIRRORS

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Template Name: OM_1_col Template Date: 1994_04_29

CP98F028

Located on the right of the engine, this reservoir is equipped with an electric pump which is controlled by two switches located in the operator’s compartment.

See "Front windshield washer switch" and “Rear windshield washer switch”.

CONTROLS/INSTRUMENTS/ACCESSORIES

FUEL TANK Template Name: OM_1_col Template Date: 1994_04_29

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 tank after each working day, to prevent the formation of condensation.

CK98F022

Located on the right-hand side of the machine, the tank capacity is 120 litres (33 US gals).

When installing the cap, make sure that it is correctly placed in the notches and then lock it by tightening up to the stop.

NOTE : The fuel cap can be locked by a key.

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

!

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

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CONTROLS/INSTRUMENTS/ACCESSORIES

When installing the cap, make sure that it is correctly placed in the notches and lock it by turning clock-wise until it stops.

CK98F023

CK98F040

The sight glass shows the level of fluid in the reservoir. See "Hydraulic system" in the "Lubrication/Filters/Fluids" section.

NOTE : Clean around the filler cap before refilling.

Template Name: OM_1_col Template Date: 1994_04_29

IMPORTANT : Use a suitable hydraulic fluid. See "Fluids and lubricants" in the "Lubrication/Filters/Fluids" section.

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Located in front of the engine, the capacity of the reservoir is 45 litres (12.4 US gals).

To refill the reservoir, see "Hydraulic system" in the "Lubrication/Filters/Fluids" section.

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HYDRAULIC RESERVOIR

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CONTROLS/INSTRUMENTS/ACCESSORIES

BATTERY MASTER SWITCH (optional) Template Name: OM_1_col Template Date: 1994_04_29

Located on the left-hand side of the machine, the battery master switch is used to disconnect the battery completely from the electrical system.

CK98F042

When the battery master switch key is removed, the circuit is disconnected.

CK98F041

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When the battery master switch key is in position, the circuit is connected.

!

WARNING : The battery master switch key (optional) must be removed after each working day, during maintenance operations and for any service work on the electrical system.

BATTERY BOX

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Tools required - Two 13 mm (1/2 inch) wrench for hexagonal head bolts To gain access to the battery, remove the retaining bolts (3 on top cover, 2 on front and 2 securing step to fender) and remove the cover.

IMPORTANT : Before carrying out any service work on the battery, see “Battery” in the “Electrical system” section.

CP99E005

Located on the left-hand side of the machine, this box contains the battery.

IMPORTANT : Remove the battery master switch key (optional) before attempting to gain access to the battery.

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CONTROLS/INSTRUMENTS/ACCESSORIES

LOADER ATTACHMENT SUPPORT STRUT

CK99E016 CK99E017

Place the strut on the cylinder rod and install the pin and “U” bar in the holes in the strut.

Locked position

!

STEP 1

WARNING : It is essential to install the safety strut when carying out any operation requiring the loader attachment to be in the raised position.

Raise the loader attachment completely, stop the engine, engage parking brake and remove the starter switch key.

Unlocked position

STEP 2

STEP 1

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Located on the left-hand side of the loader attachment, this safety strut enables the loader attachment to be secured in the raised position during inspection, service or repair.

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STEP 3

1

2

2

CK98K008

Remove the retaining pin (1) and “U” bar (2).

CD98F034

Remove the retaining pin (1) and “U” bar (2).

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Template Name: OM_1_col Template Date: 1994_04_29

1

CONTROLS/INSTRUMENTS/ACCESSORIES STEP 3

STEP 2

Template Name: OM_1_col Template Date: 1994_04_29

Start the engine and lower the loader attachment.

NOTE : Before lowering the loader attachment, make sure that the engine bonnet is closed.

CK99E016

Swing the strut against the lift arm and install the pin and “U” bar in the holes in the strut and the retaining lug.

ENGINE BONNET TRIM THIS EDGE

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CD99E002

Release the catch by means of the key.

CK98F043

Move the safety catch sideways to open the engine bonnet.

To close the bonnet, lower it and then lock it.

!

WARNING : It is essential to install the loader attachment support strut before any servicing work is done on the engine.

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CONTROLS/INSTRUMENTS/ACCESSORIES

To use this system, place the loader bucket on the ground or a few centimetres above the ground.

When the ride control system is operating, the pressure in the loader attachment lowering position is limited to that provided by the weight of the loader beams and the loader bucket. The weight of the bucket is subject to hydraulic shock absorption while the machine is travelling.

The ride control system should not be used during precise levelling operations or when an exact loader bucket position has to be observed.

1

CP98F014

!

WARNING : Never use the ride control system when using the backhoe attachment.

!

WARNING : Never operate the ride control system when the front wheels are raised off the ground. The machine could fall and cause serious injury.

IMPORTANT : Consult the service manual for any checking required on the ride control system.

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The ride control system improves the machine behaviour during travel, regardless of the type of terrain and with the loader bucket full or empty. It reduces forward and rearward pitching when moving to the rear or forwards and when carrying loads, at the same time increasing productivity and operator comfort. It also minimises impact forces to which the machine may be subjected.

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RIDE CONTROL SYSTEM (optional)

NOTE : The loader beams may rise or lower slightly when the control is operated.

When the system is no longer required, press the switch again. The indicator lamp (1) go out.

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Template Name: OM_1_col Template Date: 1994_04_29

Located on the right of the steering wheel. Press the switch. The indicator lamp (1) come on.

CONTROLS/INSTRUMENTS/ACCESSORIES

ROTATING BEACONS Template Name: OM_1_col Template Date: 1994_04_29

IMPORTANT : The rotating beacons must be installed and functioning when undertaking road travel. See "Road travel" in the "Job site and road travel" section.

NOTE : To replace the bulb, see "Replacing a bulb" in the "Electrical system" section.

CK99E018

Place the rotating beacons on the roof of the cab and connect the cable to the sockets located under the roof of the cab.

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TOOL BOX Located under the battery box, the tool box is used for storing essential parts and tools required for servicing operations.

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CP99E005

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CONTROLS/INSTRUMENTS/ACCESSORIES

After use, fold up the chock again and replace it in this housing.

WARNING : Whenever parking the machine on sloping ground, use the wheel chocks to immobilize the machine (specific to certain countries).

TOOLING The machine is supplied with the necessary tools for maintenance operations. These tools are located in the tool box : - 1 grease gun - 1 grease gun hose - 1 set of flat wrenches for hexagonal head bolts - 1 set of screwdrivers - 1 pair of pliers - 1 wrench for hexagonal socket head bolts - 2 pin drifts - 1 filter wrench - 1 hammer - 1 fuse tester - 1 coupler - 1 Allen key - 1 Hydraulic valve tool

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!

CK98K005

Unfold the wheel chock and place the chock under a wheel.

Template Name: OM_1_col Template Date: 1994_04_29

CK98K004

The wheel chock is located on the righthand stabilizer (with the operator’s seat in the loader attachment position).

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WHEEL CHOCK (specific to certain countries)

CONTROLS/INSTRUMENTS/ACCESSORIES

BACKHOE ATTACHMENT AUXILIARY HYDRAULIC TOOL CONTROLS (optional) Template Name: OM_1_col Template Date: 1994_04_29

For instructions on how to use these controls, see "Backhoe attachment auxiliary hydraulic tools" in the "Operating instructions" section.

Operating control pedal This pedal is located to the left of the backhoe control levers (with the operator’s seat in the backhoe attachment position) and enables auxiliary tools to be operated.

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CK98K001

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OPERATING INSTRUCTIONS

!

WARNING : Read and ensure that you understand 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, transmission oil, hydraulic fluid and engine coolant) 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 travel 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 of oil, mud or ice (winter) can cause accidents. Make sure they are always clean.

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- Before undertaking any road travel, lock the attachments, raise the stabilizers completely 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 side) in case access by the left-hand side is impossible.

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

- 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.

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Template Name: OM_1_col Template Date: 1994_04_29

- Make sure that the engine bonnet is closed and latched correctly.

OPERATING INSTRUCTIONS

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

!

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".

- Regularly consult the hourmeter to ensure Servicing intervals are observed. See "Servicing intervals" section.

- 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 that you know the location of underground services such as gas, electricity, telephone or mains water before starting 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 metres (118 inch).

Over 57,000 volts : 5 metres (197 inch).

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- 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.

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

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

- When towing the machine, see "Towing the machine”.

- Load lifting should be carried out in accordance with the instructions given in this manual and in accordance with prevailing regulations. See "Load lifting".

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

- If there is any operating problem or damage move the machine to a place of safety, stop the engine, engage parking brake, remove the starter switch key.

Find the cause or contact your CASE Dealer take the necessary measures to forbid the use of the machine. Place a "Do not start up" label on 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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- If the machine has to work in water, see "Operating the machine in water".

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OPERATING INSTRUCTIONS

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

Your machine will last longer and give better and more economical performance if you pay particular attention to the engine during the first twenty hours of operation.

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

Check the oil and engine coolant 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 :

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AFTER THE FIRST 50 OPERATING HOURS

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1.

Change engine oil and filter. See “Engine” in the “Lubrication/Filters/Fluids” section.

2.

Change hydraulic oil filter. See “Hydraulic system” in the “Lubrication/Filters/ Fluids” section.

3.

Check air filter. See “Air filter” in the “Lubrication/Filters/Fluids” section.

4.

Change transmission oil and filter. See “Transmission” in the “Lubrication/Filters/ Fluids” section.

5.

Clean transmission strainer. See “Transmission” in the “Lubrication/Filters/Fluids” section.

6.

Change front and rear axle oils. See “Front and rear axles and reduction gears” in the “Lubrication/Filters/Fluids” section.

7.

Check reduction gear oil levels. See “Front and rear axles and reduction gears” in the “Lubrication/Filters/Fluids” section.

8.

Check road wheel nuts for tightness daily until stabilised. See “Wheels and tyres” in the “Maintenance/Adjustment” section.

Rear : 300 Nm (220 lbf ft), Front : 300 Nm (220 lbf ft).

This wheel nut checking procedure also must be applied for any wheel which is removed and replaced, for any reason.

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OPERATING INSTRUCTIONS Check fan belt tension. See “Engine alternator and fan belt” in the “Maintenance/ Adjustment” section.

10. Reset engine valve tip clearance. See “Engine valve tip clearance adjustment” in the “Maintenance/Adjustment” section.

11. Check brake adjustment. See “Brake check and adjustment” in the “Maintenance/Adjustment” section.

12. Check bolt torques on cardan shafts to front and rear axles. See “Steering and axles” in the “Maintenance/Adjustment” section.

13. Check bolt torques on transmission mounting bolts. See “Transmission” in the “Maintenance/Adjustment” section.

Template Name: OM_1_col Template Date: 1994_04_29

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14. Check the automatic loader bucket levelling for correct adjustment and operation.

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9.

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OPERATING INSTRUCTIONS

STARTING THE ENGINE 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 the machine" section.

STEP 3 Adjust the seat and attach the seat belt.

STEP 4

NOTE : If you have to start the engine by means of a booster battery, see "Connecting a booster battery" in the "Electrical system" section.

STEP 1

CK99E002

Check that the parking brake is engaged.

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STEP 5

CK98F041

Connect the electrical system by means of the battery master switch key. (optional)

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STEP 2

CK99E002

Check the engine throttle lever is in low idle position.

CK99E019

Check that the seat is properly locked in the loader attachment working position.

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OPERATING INSTRUCTIONS STEP 6

2 CP99D002

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

STEP 7

CS98G565

Turn the starter switch key to the "ON" position. Warning lights (2) and (10) should light up.

If necessary, replace the defective bulbs.

See "Replacing a bulb" in the "Electrical system" section.

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Check that the direction of travel lever is in the neutral position.

STEP 9

CP99E003

Check that the gear change lever is in the neutral position.

CK99D004

Press the accelerator pedal down about a quarter of the way.

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Template Name: OM_1_col Template Date: 1994_04_29

10

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STEP 8

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 10

Template Name: OM_1_col Template Date: 1994_04_29

STEP 12 When the engine is running check the indicators and indicator lamps to make sure that all systems are operating correctly.

STEP 13 CP99D009

Turn the starter switch key to the pre-heat position and hold it there.

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IMPORTANT : For a temperature over 5°C, hold the key in the pre-heat position for ten seconds. For a temperature of between -5°C and +5°C, hold the key in position for twenty seconds. For a temperature below -5°C, hold the key in position for thirty seconds. Never hold the key in the pre-heat position for more than one minute.

Using the accelerator pedal, run the engine at half speed until it has reached normal operating 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.

STEP 11

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CP99D009

Turn the key to the starting position.

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

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OPERATING INSTRUCTIONS

STARTING UP IN NORMAL CONDITIONS STEP 2

STEP 1 Start the engine (See “Starting the engine”).

CP99D009

Template Name: OM_1_col Template Date: 1994_04_29

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When you are ready to work and it is sure that nobody is standing within the working range of the machine, press the hydraulic enable switch once.

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The electronic controls of the machine are protected by a number of safety devices which make it impossible to drive the machine or use the loader attachment in certain circumstances.

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OPERATING INSTRUCTIONS

STARTING UP SAFETY DEVICES Template Name: OM_1_col Template Date: 1994_04_29

!

WARNING : The rear wheels can turn upon starting up and injure bystanders.

The machine’s onboard computor has a special programme which disengages the rear steering wheels and the transmission immediately the engine is started.

The operator has to carry out a number of special operations to enable the system.

STEP 4

The various safety devices do not function if the machine is parked with the wheels facing forwards.

STEP 1 Start the engine (See “Starting the engine”).

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STEP 2

CK99E004

Select any other steering mode. The rear wheels will immediately take up the position corresponding to the steering mode selected and the transmission engages.

STEP 5 Select the steering mode required.

STEP 6

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CK99E004

If the steering mode switch position does not correspond to the position of the machine’s wheels, the rear steering wheels and the transmission will not function and four warning “beeps” will be heard.

STEP 3 Make sure nobody is standing within the working range of the machine.

CP99D009

Press the hydraulic function enable switch to enable the loader attachment controls.

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OPERATING INSTRUCTIONS

Emergency cut-out button

IMPORTANT : Before leaving the cab or undertaking any road travel, it is essential for the operator to cancel the loader attachment controls.

Loader or backhoe attachment selector button (595LSP type)

Hydraulic system enabling switch CK99E013

CP99D009

This switch is used to enable the hydraulic system. It lights up when the hydraulic system is enabled. To disactivate the system, press the switch and the light will go out.

this switch reverses all the computer information concerning the seat position and allows the operator to use the tool mounted behind him (for example, he may wish to lower the backhoe slightly when going through a doorway).

Although this feature is necessary and extremely useful, it can also prove to be very dangerous if the operator forgets the controls no longer operate the same functions. For this reason the computer emits an audible warning each time the switch is pressed. The audible warning ceases as soon as the switch is released and the control pattern returns to normal.

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CP99D009

This button makes it possible to cancel all attachment controls. The loader and rear steering movements will stop.

Template Name: OM_1_col Template Date: 1994_04_29

The electronic system of the machine is self-diagnosing and provides the operator with warning signals in the form of “beeps”. The functioning mode of the computer is also affected by three switches.

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ELECTRONIC SYSTEM

OPERATING INSTRUCTIONS

Template Name: OM_1_col Template Date: 1994_04_29

!

WARNING : Before operating the Loader or backhoe attachment selector button, make sure nobody is standing within the working range of the attachments.

!

WARNING : When using the loader or backhoe attachment selector button, operate all controls gradually to ensure smooth movement.

Fault warnings On the side control panel is a device which emits a “beep” sound. This alarm system operates when the computor detects a fault which affects operation or safety.

Fault condition ■ ..........

1 short “beeps”

Problem

Corrective action

The seat is not properly Move the seat forwards slightly. locked in an operating When properly positioned the seat position. should not swivel.

(595LSP only)

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■■ ..........

Emergency stop button Unlock emergency stop button. is locked off.

1 long “beeps” ■ ■ ..........

2 short “beeps”

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There is a fault in the Visually check for damage to the loader levelling system. potentiometers on the loader pivot.

Also inspect the wiring and connectors for damage. If there is no obvious reason for malfunction, call your CASE Dealer immediately.

The machine must not be operated until the fault is corrected.

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OPERATING INSTRUCTIONS Problem

Corrective action

There is a fault in the Visually check for damage to the loader bucket levelling potentiometers on the bucket linkage pivot. Also inspect the 1 short and 1 long system. wiring and connectors for damage. “beeps” If there is no obvious reason for malfunction, call your CASE Dealer immediately. The machine must not be operated until the fault is corrected.

■ ■ ■..........

3 short “beeps”

Faulty control lever It is dangerous to operate the signal – right-hand. machine with this fault as erratic movements may occur. If “beeps” stop when the seat is facing forward (loader operations), the fault is in the left control lever. If the “beeps” continue irrespective of the seat position the fault is in the right control lever.

Faulty control lever It is dangerous to operate the signal – left-hand. machine with this fault as erratic movements may occur. If “beeps” 2 short and 1 long stop when the seat is facing forward “beeps” (loader operations), the fault is in the (595LSP only) left control lever. If the “beeps” continue irrespective of the seat position the fault is in the right control lever.

Template Name: OM_1_col Template Date: 1994_04_29

■ ■ ■■..........

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■ ■■ ..........

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Fault condition

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OPERATING INSTRUCTIONS Fault condition

Template Name: OM_1_col Template Date: 1994_04_29

■ ■ ■ ■ ..........

4 short “beeps”

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■ ■ ■ ■■..........

Problem

Corrective action

Steering error : This warning sounds during start-up, if the steering wheel position does not agree with the mode selected.

Select the steering mode corresponding to the position of the machine’s wheels. The audible alarm will cease sounding.

The alarm sounds during work.

- If the fault is in the front axle, switch to 2 wheel steer and the warning will stop.

If the fault is in the rear axle, the rear steering will “freeze”.

Call your CASE Dealer immediately and describe the symptoms that you have found. The machine must not be operated until the fault is corrected.

Invalid steer mode.

Machine will revert to 2WS and continue sounding alarm until 2WS mode selected.

Rear wheel alignment.

Visually check for damage to the potentiometers on the rear axle.

Also inspect the wiring and connectors for damage. If there is no obvious reason for malfunction, call your CASE Dealer immediately.

The machine must not be operated until the fault is corrected.

3 short and 1 long “beeps” ■ ■ ■ ■ ■ .........

5 short “beeps”

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OPERATING INSTRUCTIONS Corrective action

Front wheel alignment.

4 short and 1 long “beeps”

■ ■ ■ ■ ■ ■.......

6 short “beeps”

Visually check for damage to the potentiometers on the front axle.

Also inspect the wiring and connectors for damage. If there is no obvious reason for malfunction, call your CASE Dealer immediately.

The machine must not be operated until the fault is corrected

2 wheel steer alignment Visually check for damage to the fault. potentiometers on the rear axle.

Also inspect the wiring and connectors for damage. If there is no obvious reason for malfunction, call your CASE Dealer immediately.

The machine must not be operated until the fault is corrected.

4 wheel steer alignment Visually check for damage to the fault. potentiometers on the rear axle.

Also inspect the wiring and 5 short and 1 long connectors for damage. If there is “beeps” no obvious reason for malfunction, call your CASE Dealer immediately.

The machine must not be operated until the fault is corrected.

■ ■ ■ ■ ■ ■■....

WARNING : Any malfunction must be reported to your CASE Dealer immediately.

Template Name: OM_1_col Template Date: 1994_04_29

!

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■ ■ ■ ■ ■■ .......

Problem

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Fault condition

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OPERATING INSTRUCTIONS

STOPPING THE ENGINE STEP 3.

STEP 1

Template Name: OM_1_col Template Date: 1994_04_29

CP99D002

Place the direction of travel control lever in the neutral position.

STEP 2

CK99E002

Apply parking brake securely.

STEP 4

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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 5

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CP99E003

Place the gear change lever in the neutral position.

CP99D009

Turn the starter switch key to the “OFF” position and remove the starter switch key.

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

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OPERATING INSTRUCTIONS

OPERATING THE MACHINE IN COLD WEATHER Engine oil

It must be fully charged.

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

a) Refill the fuel tank after each working day to prevent the formation of condensation and the entry of water into the fuel system. b) To prevent the formation of crystals (-2°C) use a low temperature fuel or mix a protective fluid with your fuel.

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

Engine coolant 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.

OPERATING THE MACHINE IN HOT WEATHER Observe the following recommendations : 1.

Maintain the correct level of engine coolant in the engine coolant reservoir.

2.

Check the condition of the radiator cap before starting. Replace the cap if necessary.

3.

Clean the radiator, the oil cooler and the engine carefully.

4.

Check the condition of the alternator and fan belt.

5.

Use lubricants with the recommended decree of viscosity. See "Fluids and lubricants" in the "Lubrication/Filters/ Fluids" section.

6.

Use an appropriate engine coolant (a mixture or ethylene glycol and water at the required concentration).

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

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Fuel

Template Name: OM_1_col Template Date: 1994_04_29

Battery

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Observe the following recommendations :

OPERATING INSTRUCTIONS

SETTING THE MACHINE IN THE BACKHOE ATTACHMENT WORKING POSITION Template Name: OM_1_col Template Date: 1994_04_29

!

WARNING : Any uncontrolled movement of the machine can cause an accident. Before turning the operator’s seat to the backhoe attachment working position, it is essential to place the direction of travel control lever and the gear change lever in the neutral position, the parking brake engaged.

!

WARNING : Before using the backhoe attachment, place the seat in the backhoe attachment position. Always sit in the seat and attach the seat belt.

Serious injury can result if these instructions are not observed.

STEP 2

STEP 1

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Check that the direction of travel control lever is in the neutral position.

CP99E003

Make sure that the gear change lever is in the neutral position.

STEP 3

CK99E002

Make sure that the parking brake is engaged.

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OPERATING INSTRUCTIONS STEP 5 with

standard

loader

CK99E020

STEP 6 TRIM THIS EDGE

CD99E003

Start the engine. Place the loader bucket in the dumping position. Lower the bucket to the ground until the front wheels are about 10 cm (4 inch) above the ground.

Turn the seat round to the backhoe attachment position and adjust if necessary.

(Machine with 7 in 1 loader bucket)

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STEP 4 (Machine bucket)

CD99E004

Start the engine. Place the loader bucket in the level position. Lower the bucket to the ground until the front wheels are about 10 cm (4 inch) above the ground.

IMPORTANT : Normal engine speed when working is 1500-1800 rev/min. maximum. However, operate at a lower speed until operating skill develops.

Switch to “Low flow” when working in very restricted conditions, particularly around underground cables or pipes and especially if other workers are in the vicinity. 1800 rev/min. should not be exceeded for backhoe work.

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Template Name: OM_1_col Template Date: 1994_04_29

CK99E004

Accelerate and run the engine at the required speed.

OPERATING INSTRUCTIONS STEP 9

STEP 7

Template Name: OM_1_col Template Date: 1994_04_29

Lower the stabilizers. The rear wheels must be about 10 cm (4 inch). off the ground and the machine must be in a horizontal position.

IMPORTANT : Whenever the backhoe attachment is used the machine must be resting on the stabilizers.

!

WARNING : Before operating the backhoe, ensure that no person is within its working range.

CD98G004

When using the extendable dipper (if equipped) make sure that the pin is placed in the external stowage bracket.

STEP 8

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!

WARNING : Before starting work, make sure that no person is within the working range of the machine.

!

WARNING : Before starting work, check that all the backhoe controls operate correctly.

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CK98F035

CK97N041

Raise the boom. Pull the lever up to release the lock.

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OPERATING INSTRUCTIONS

To dig alongside a building or fence, etc., it is possible to shift the backhoe equipment sideways to the right or the left.

STEP 1

STEP 4

The machine must be in the backhoe attachment position, see “Setting the machine in the backhoe attachment working position”.

Operate the backhoe attachment controls alternately so as to slide the sideshift carriage sideways.

STEP 5 Once the attachment is in the side position required, swing it round into alignment with the machine.

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STEP 6

CD98K013

Place the backhoe attachment on the left if you want to shift the attachment to the right or place it on the right if you want to shift it to the left, then place the attachment on the ground in the position shown.

STEP 3

CP99D009

Press the sideshift locking switch again to lock the sideshift. The indicator lamp will go out.

CP99D009

Press the sideshift unlocking switch. The indicator comes on.

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Template Name: OM_1_col Template Date: 1994_04_29

STEP 2

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BACKHOE ATTACHMENT SIDESHIFT (sideshift (offset) backhoe version)

OPERATING INSTRUCTIONS

SETTING THE BACKHOE ATTACHMENT IN THE ROAD TRAVEL POSITION Template Name: OM_1_col Template Date: 1994_04_29

IMPORTANT : This procedure must be used for road travel, for securing the loader attachment, when transporting the machine on a trailer and when parking the machine.

STEP 3

STEP 1

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CP99D002

CK99E002

Check that the direction of travel control lever is in the neutral position.

Make sure that the parking brake is engaged.

STEP 2

STEP 4

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CP99E003

Make sure that the gear change lever is in the neutral position.

CK99E020

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

STEP 5 Make sure that the machine is resting on the stabilizers and the loader bucket.

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OPERATING INSTRUCTIONS STEP 6

(Sideshift (offset) backhoe version), swing the backhoe attachment completely to the left.

1

STEP 12

2 CD98G004

Retract the extendable dipper (if equipped) completely and place the pin (1) in the extendable dipper locking hole (2).

(Sideshift (offset) backhoe version), position the backhoe attachment sideshift carriage completely to the right. See “Backhoe attachment sideshift”.

Release the boom lock lever by depressing the button and lowering the lever. It may be necessary to make small adjustments to the boom position before the lock will fully engage.

STEP 8

STEP 13

Place the backhoe attachment in line with the machine.

Raise the stabilizers completely.

STEP 9

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CK97N041

STEP 7

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STEP 11

STEP 14 Run the engine at low idle speed.

Turn the seat round to the loader attachment position. Raise the loader bucket.

NOTE : It may be necessary to increase engine rpm to give suitable pump flow for quick attach to function.

CK99E002

Run the engine at about 900 rpm.

STEP 10 Completely retract the backhoe bucket, dipper and boom.

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Template Name: OM_1_col Template Date: 1994_04_29

STEP 15

OPERATING INSTRUCTIONS

REPLACING A BACKHOE BUCKET Template Name: OM_1_col Template Date: 1994_04_29

NOTE : This is a delicate operation. We advise you to obtain the assistance of a second person.

STEP 4

IMPORTANT : Before carrying out this operation make sure that no other person, apart from the signalman, is within the machine’s working range.

STEP 1 Park the machine on flat, level ground.

STEP 2 CD95M244

Lower the stabilizers until the rear wheels are just clear of the ground.

Remove the dipper/bucket linkage pin retaining pin.

STEP 3

STEP 5

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CD95M245

Place the bucket in the vertical position.

CD95M246

Remove the dipper/bucket linkage pin.

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OPERATING INSTRUCTIONS

Retract the bucket cylinder so as to pivot the bucket until the holes in the bucket lugs are in line with the hole at the end of the dipper.

STEP 10 CD95M247

Using the attachment, carefully pivot the bucket and lay it down on the ground.

STEP 7

NOTE : To install the second bucket, it must be in upturned position on the ground.

IMPORTANT : Clean the coupling hook if necessary.

CD95M246

Install the dipper/bucket pin.

STEP 11

STEP 8

CD95M244 CD95M247

Install the pin retaining pin.

Using the attachment, bring the coupling hook around the bucket.

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Using the attachment, carefully disconnect the bucket coupling hook.

Template Name: OM_1_col Template Date: 1994_04_29

STEP 9

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IMPORTANT : Make sure that the coupling hook is correctly engaged around the bucket pin.

STEP 6

OPERATING INSTRUCTIONS

REMOVAL AND INSTALLATION OF QUICK ATTACH LOADER BUCKET (optional) Template Name: OM_1_col Template Date: 1994_04_29

Removal

STEP 3

STEP 1

CP98F014

CS98G543

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Place the loader bucket on a flat, level ground, stop the engine, engage parking brake, remove the starter switch key and release pressure in the hydraulic system.

Start the engine, press and hold the switch down to unlock the loader quick attach. See “Loader quick attach locking/ unlocking switch” in the “Controls/Instruments/Accessories” section.

STEP 4

STEP 2

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4

1

3 2 CS98G542 CS98G543

Disconnect the hoses from the bucket couplers (1) and connect to the solenoid valve (2) and tube (3).

Push the clamshell operating lever forward until the clamp pins on the quickattach are fully retracted (indicator (4) raised clear of the tube).

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OPERATING INSTRUCTIONS

5

CS98G542

CS98G542

Installation

Press and hold the switch, then push the clamshell operating lever forward until the clamp pins on the quick-attach are fully retracted (indicator (5) raised clear of the tube). Move the clamshell lever to the neutral position and release the switch.

STEP 1

STEP 3

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With the bucket on the ground, slowly drive the machine in reverse whilst dumping the bucket to disengage the quickattach hooks from the bucket pins.

1 1 3

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STEP 2

STEP 5

3

4

CS98G542

Position the hooks (1) and (2) in alignment with the bucket pins (3) and (4). The quick-attach must be slightly dumped.

CS98G542

Engage the top hooks (1) with the top pins (3) then fully crowd the bucket.

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Template Name: OM_1_col Template Date: 1994_04_29

2

OPERATING INSTRUCTIONS STEP 6

STEP 4

Template Name: OM_1_col Template Date: 1994_04_29

5

8 6 7 CS98G542

Press and hold the switch, then pull back the clamshell operating lever to lock the bucket onto the quick-attach (indicator (5) retracted into the tube). Allow sufficient time for both pins to lock.

CS98G543

Disconnect the hoses from the solenoid valve (6) and tube (7) and connect them to the bucket couplers (8).

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STEP 5 Place the bucket onto the ground, stop the engine, engage parking brake, remove the starter switch key and release pressure in the hydraulic system.

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OPERATING INSTRUCTIONS

The differential lock gives equal power to both rear wheels. It is particularly useful when the wheels have insufficient adhesion, as in the following cases : IMPORTANT : Never use the differential lock during travel on a public highway.

IMPORTANT : Do not engage the differential when 4 wheel steering or crab steering have been selected

When the machine is stuck

STEP 4

STEP 1

STEP 5

Release the transmission dump button.

Make sure that the rear wheels are not turning.

CK99D004

Use the accelerator pedal to increase the engine speed.

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STEP 2

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DIFFERENTIAL LOCK

STEP 6 Push down the transmission dump button.

STEP 3

Stop the machine. Push down the clutch cut-out button and then release the differential lock pedal.

Before crossing a soft or muddy area NOTE : You can engage the differential lock when the machine is moving in a straight line.

STEP 1 Make sure that the machine is moving in a straight line and that both rear wheels are turning at the same speed.

CK99D004

Push down the differential lock pedal and hold it down.

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Template Name: OM_1_col Template Date: 1994_04_29

CK99E011

OPERATING INSTRUCTIONS STEP 2

Template Name: OM_1_col Template Date: 1994_04_29

CK99D004

Push down the differential lock pedal and hold it down while you move the machine through the soft of muddy area.

STEP 3

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After you have moved through the area, stop the machine push down the clutch cut-out button and then release the differential lock pedal.

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IMPORTANT : You can cause damage to the transmission if you try to engage the differential lock when the machine is turning or if one rear wheel is rotating faster than the other rear wheel.

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OPERATING INSTRUCTIONS

Before using auxiliary tools, it is necessary to proceed as follows : - Place the direction of travel control lever in neutral position.

- Place the gear change lever in neutral.

- Lower the loader bucket until it is pressing on the ground.

Press the heel of the pedal to supply oil through coupler (2) and return oil through coupler (1).

It is up to the operator to decide which flow should be used by consulting the manufacturer’s operating instructions. Be sure to select the flow recommended.

Excess flow can damage some equipment.

1 2

CP98F016

Stop the engine, engage parking brake, release hydraulic pressure and remove the starter switch key, connect the tool hoses to (1) and (2) couplers located on the backhoe dipper.

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Flow mode selection

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BACKHOE ATTACHMENT AUXILIARY HYDRAULIC TOOLS (optional)

CK99E002

Flow rate setting depends on the engine speed.

CK98K001

Press the toe of the pedal to supply oil through coupler (1) and return oil through coupler (2).

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Template Name: OM_1_col Template Date: 1994_04_29

NOTE : The (1) coupler is the coupler used to supply percussion tools, such as hydraulic hammers, compaction tools, tampers, etc...

OPERATING INSTRUCTIONS

LOAD LIFTING Template Name: OM_1_col Template Date: 1994_04_29

!

WARNING : Load lifting must be carried out in accordance with the instructions shown in this manual and in accordance with current regulations.

For load lifting, it is essential that the machine is equipped with a load fixing point.

For lifting operations above 1000 kg, it is a legal requirement for the fitment of hose burst lockout valves on specific services.

To lift a load, the following instructions must be followed : - Place the machine on flat, hard, level ground.

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- Lower the loader attachment until the front wheels just touch the ground without supporting the weight of the machine.

- Lower the stabilizers until the rear wheels just touch the ground without supporting the weight of the machine.

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- It is mandatory for the backhoe attachment to be in line with the machine and the sideshift carriage to be locked hydraulically (sideshift (offset) backhoe version).

- Use the load fixing point (never use other load fixing points). See "Maximum working loads". It is forbidden to weld hooks or lugs to the bottom of buckets.

- Use slings and chains in perfect condition, able to support the load to be lifted and with an effective device preventing the slings or chains becoming unhooked.

- Check that the safety valves operate correctly. A pressure setting check must be carried out every six months in accordance with the manufacturer’s instructions. Consult your CASE Dealer.

- Do not allow any person within the machine’s working range.

- Use the controls gradually so as to move the attachment accurately.

- If the machine is equipped with a extendable dipper, it is mandatory for it to be completely retracted and mechanically locked.

- It is essential for the backhoe bucket cylinder rod to be completely extended.

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OPERATING INSTRUCTIONS

IMPORTANT : The Safe Working Load of the backhoe is calculated using a standard bucket, therefore, when using any other bucket or attachment for “lifting” or “craning” the weight of the bucket or attachment must be taken into account when calculating the rated load of the backhoe.

IMPORTANT : The Safe Working Load of the loader is calculated using a standard bucket, therefore, when using any other bucket or attachment for “lifting” or “craning” the weight of the bucket or attachment must be taken into account when calculating the rated load of the loader.

Safe Working Load

Safe Working Load

595SLE Type = 1000 kg (2204 lbs)

595SLE Type = 1000 kg (2204 lbs)

595LSP Type = 1000 kg (2204 lbs)

595LSP Type = 1000 kg (2204 lbs)

The loader bucket and the stabilizers must be pressing on the ground and the machine must be level.

It is mandatory for the backhoe attachment to be in the central axis of the machine.

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The machine must be on flat, hard and level ground.

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MAXIMUM WORKING LOADS Backhoe attachment Loader attachment

Template Name: OM_1_col Template Date: 1994_04_29

The extendable dipper (if equipped) must be in the completely retracted position and must be mechanically locked.

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OPERATING INSTRUCTIONS

LOADER BUCKET MOUNTED FORKS (optional) Template Name: OM_1_col Template Date: 1994_04_29

!

WARNING : The forks are heavy, so use great care when swinging them into their working and stowage position.

Install forks in working position

STEP 4

STEP 1 Place the loader bucket onto the flat level ground stop the engine, engage parking brake and remove the starter switch key.

4

3

STEP 2

1 CP99E007

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Hold the fork and remove the retained pin (3) and the pin (4).

STEP 5

2 CP99E006

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Remove the retained pin (1) and the pin (2).

STEP 3

CP99E008

Lower the fork into position against the bucket cutting edge.

CP99D006

Lower the bracket.

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OPERATING INSTRUCTIONS

STEP 1 Place the bucket onto the flat level ground, stop the engine, engage parking brake and remove the starter switch key.

STEP 2

3 CP99E008

Install the pin (4) and the retained pin (3).

STEP 7 Repeat steps 2 to 6 for the other fork.

4

Slide the forks until they are suitably spaced for the intended job.

IMPORTANT : The both forks must be spaced equally each side of the centre of the bucket.

CP99E008

Remove the retained pin (1) and the pin (2).

STEP 3

IMPORTANT : The forks must be lying against the cutting edge, not against the bucket teeth.

2

1

CP99E007

Raise the fork and install the pin (2) and the retained pin (1).

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3

STEP 8

Template Name: OM_1_col Template Date: 1994_04_29

4

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Install the forks in rest position

STEP 6

OPERATING INSTRUCTIONS STEP 4

Template Name: OM_1_col Template Date: 1994_04_29

CP99D006

Raise the bracket.

NOTE : If necessary slide the fork to bring is into its housing.

STEP 5

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4

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3 CP99E006

Install the pin (3) and the retained pin (4).

STEP 6 Repeat steps 2 to 5 for the other fork.

IMPORTANT : The forks must be securely retained in their proper stowage positions using the correct pins and linch pins. Improperly stowed forks may be cause sections injury.

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OPERATING INSTRUCTIONS

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

On the trailer of an articulated vehicle

Make sure you know the safety rules and regulations before transporting this machine. Make sure that the articulated vehicle and the machine are fitted with the correct safety equipment.

Loading STEP 1

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STEP 4

CD95M248

CP99E003

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

Place the gear change lever in first gear and load the machine carefully onto the trailer.

STEP 2

STEP 5

Place the backhoe attachment in the road travel position. See "Setting the backhoe attachment in the road travel position”.

Lower the loader attachment so that the bucket is resting on the bed of the trailer.

STEP 3 Raise the loader bucket about 20 cm (8 inch) above the ramps.

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Template Name: OM_1_col Template Date: 1994_04_29

!

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.

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On a railway wagon

OPERATING INSTRUCTIONS STEP 6

STEP 9

Template Name: OM_1_col Template Date: 1994_04_29

CK99E002

Engage the parking brake and place the direction of travel control lever and gear change lever in the neutral position.

CD98F075

Turn the rear view mirrors inwards.

STEP 10 Use chocks and chains to secure the machine and the loader attachment on the trailer.

STEP 7

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STEP 11 Measure the distance between the ground and the highest point. You must know the total height.

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IMPORTANT : After a short distance, check that the machine has not moved and that the chains are still under tension.

CP99D009

Stop the engine and remove the starter switch key.

STEP 8 Make sure the windows, doors and engine bonnet are closed and correctly fastened.

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OPERATING INSTRUCTIONS

Unloading Remove the chocks and the retaining chains.

STEP 2 Return the rear view mirrors to their correct position.

STEP 3 Start the engine.

STEP 4 Raise the loader attachment to bring the bucket clear of the bed of the trailer.

Release the parking brake and place the gear change lever in first gear.

STEP 6

Template Name: OM_1_col Template Date: 1994_04_29

Slowly reverse the machine, so as to keep the loader attachment permanently a few centimetres above the bed of the trailer and the ramps.

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STEP 5

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STEP 1

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OPERATING INSTRUCTIONS

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

IMPORTANT : Before lifting the machine, it is essential to place the backhoe attachment in the road travel position. See "Setting the backhoe attachment in the road travel position”.

Use suitable slings to lift the machine.

Make sure that the slings are in perfect condition and that they can take the weight of the machine. See "Machine weights" in the "Specifications" section.

!

WARNING : Do not allow anybody within the machine's working range. Never swing the machine over people who are in proximity.

NOTE : See "Machine weight" in the "Specifications" section.

CD99D022

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The lifting points for the machine are shown by decals. See "Decals" in the "Safety/Decals/Hand Signals" section.

IMPORTANT : Never use any other lifting points than those shown by the decals.

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OPERATING INSTRUCTIONS

TOWING THE MACHINE First of all make sure that it can be towed without causing further damage.

Whenever possible carry out the repair at the site or consult your CASE Dealer.

!

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. Whenever possible, carry out the repair at the location, without towing the machine.

!

WARNING : The machine must be towed very slowly (16 kph maximum), over a short distance and only if it is really necessary.

!

WARNING : It is essential for a tow bar to be used for towing the machine.

!

WARNING : When towing the operator must be alone on the machine.

Make sure that no other person is on the machine or within the machine’s working range.

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If the machine is on the public highway, make sure that no component of the machine projects onto the highway. If this cannot be avoided, install signs in accordance with regulations.

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The machine should only be towed when it is undriveable.

1.

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

2.

The level of the water must not exceed the height of the centre of the front wheels.

IMPORTANT : Never work in water if the water level is higher than the centre of the front wheels.

3.

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

IMPORTANT : Never work in fast-flowing water.

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Template Name: OM_1_col Template Date: 1994_04_29

OPERATING THE MACHINE IN WATER

OPERATING INSTRUCTIONS

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

STEP 1

STEP 5

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

Stop the engine, remove the starter switch key and release the hydraulic pressure. See “Releasing the pressure in the hydraulic system” in the “Lubrication/Filters/Fluids”.

STEP 2 Lower the loader bucket to the ground.

STEP 6

STEP 3

Lock the operator's compartment doors.

Engage the parking brake and place the direction of travel control lever and gear change lever in neutral position.

STEP 4

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Place the backhoe attachment in the road travel position. See "Setting the backhoe attachment in the road travel position”.

STEP 7 Disconnect the electrical system by means of the battery master switch key.

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

!

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

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OPERATING INSTRUCTIONS

!

WARNING : Great care must be taken when carrying out this operation to avoid being injured by the wheels or the axle as they move. The rear wheels must be raised clear of the ground with the machine resting on firm supports.

CS97N085

Template Name: OM_1_col Template Date: 1994_04_29

Mount the lever over the small pin protruding from the side of the spool.

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Providing the engine is running, the spool of the steering control valve can be operated manually to change the direction in which the rear wheels are pointing. Each machine is delivered with an articulated lever and control rod. If necessary, you can connect the lever to the steering control valve spool, working from underneath the machine.

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MANUAL OPERATION OF THE STEERING CONTROL VALVE

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OPERATING INSTRUCTIONS

MANUAL OPERATION OF THE LOADER ARMS Template Name: OM_1_col Template Date: 1994_04_29

In the event of an electrical system failure (or a loss of pilot pressure) occurring when the bucket is loaded or in raised position, it is possible to operate the loader arms manually. This can also be useful in the event of a breakdown when the machine has to be brought in for repairs.

!

Each machine is delivered with an articulated lever and control rod. If necessary, you can connect the lever to the loader arm control valve spool, working from underneath the machine.

WARNING : - Before lowering the arms, the engine must be stopped.

- Before operating the arms manually, make sure the ride control switch is off and keep well clear of the loader.

- Never remain within the working range of the rear wheels.

- Engage the parking brake.

- Place chocks under the wheels.

- Place all transmission controls in neutral.

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CS97N085

Mount the lever over the small pin protruding from the side of the spool. Push the lever upwards to lower the loader arms and, providing the engine is running, pull it downwards to raise them.

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OPERATING INSTRUCTIONS

In the event of an electrical system failure (or a loss of pilot pressure) occurring when the bucket is loaded or in raised position, the boom can be operated manually. This can also be useful in the event of a breakdown when the machine has to be brought in for repairs.

!

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Each machine is delivered with an articulated lever and control rod. If necessary, the lever can be connected to the boom control valve spool and operated in perfect safety from within the cab, by pushing or pulling it. Access to the control valve is obtained via a plate in the floor.

WARNING : - Before lowering the boom, the engine must be stopped.

- Keep wall clear of the boom while operating the boom control valve manually.

- Engage the parking brake.

- Place chocks under the wheels.

- Place all transmission controls in neutral.

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MANUAL OPERATION OF THE BACKHOE ATTACHMENT (595LSP)

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Template Name: OM_1_col Template Date: 1994_04_29

CS97N086

Mount the lever over the small pin protruding from the side of the spool. Push the lever downwards to lower the boom and, providing the engine is running. Pull it upwards to raise the boom.

JOB SITE AND ROAD INSTRUCTIONS

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

!

WARNING : Observe the instructions for use shown 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 carrying out any road travel, lock the attachments 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.

- Raise the stabilizers completely.

- Check that the lighting and signalling systems operate correctly.

- Check that the brakes and steering operate correctly.

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- Check the condition and pressure of the tyres.

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

- Never use the differential lock.

- All road travel should be undertaken with the front drive axle disengaged.

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 the slope keep the loader bucket at ground level.

- When travelling in the same direction as the slope, move onto the slope in low gear (first gear). Never travel down slopes with the gear change lever in the neutral position.

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JOB SITE AND ROAD INSTRUCTIONS

- Holes, obstacles, debris and other hazards in the working area can cause serious physical injury. Always walk around and identify all possible hazards before operating the machine in a new working area.

- Do not work close to live overhead electric lines without first making sure that the minimum distances are observed : Under 57,000 volts : 3 metres (118 inch).

Over 57,000 volts : 5 metres (197 inch).

!

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

!

WARNING : It is essential to lock the attachments and install the safety systems required by regulations before travelling on the road.

!

WARNING : Check that the lighting and signalling systems are operating correctly before travelling on the road.

!

WARNING : Before undertaking any road travel, make sure that the backhoe attachment is in the road travel position and mechanically immobilized.

STEP 2

Place the backhoe attachment in the road travel position. See "Setting the backhoe attachment in the road travel position" in the "Operating instructions" section.

CK99E002

Make sure that the engine throttle lever is in the low idle position.

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Template Name: OM_1_col Template Date: 1994_04_29

STEP 1

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ROAD TRAVEL

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- When working on a slope, engage the front drive axle.

JOB SITE AND ROAD INSTRUCTIONS STEP 7

STEP 3

Template Name: OM_1_col Template Date: 1994_04_29

Make sure the stabilizers are completely raised.

STEP 4

CD98F075

Adjust the rear view mirrors correctly.

STEP 8 CK99E019

Place the seat in the loader attachment position.

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STEP 5 Raise the loader attachment about 20 cm (8 inch). above the ground and roll back the loader bucket completely. Stop the engine, e ngage p arking brake and remove the starter switch key.

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STEP 6

CK99E018

Place the rotating beacons on the cab roof and connect the cables.

STEP 9 Make sure that the doors are closed correctly and that the engine bonnet is fastened.

CP98D028

Install the tooth-cover and the warning panels on the loader bucket (optional or specific to certain countries).

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JOB SITE AND ROAD INSTRUCTIONS

CK99E007

Adjust the operator’s seat correctly.

Fasten the seat belt.

CP99D009

Press the emergency cut-out button.

STEP 13

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STEP 11

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STEP 12

STEP 10

CK99E004

Make sure that the direction of travel control lever is in the neutral position and start the engine.

Make sure the steering mode switch is in two wheel steering position and that it is locked with the tab.

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Template Name: OM_1_col Template Date: 1994_04_29

CP99D002

JOB SITE AND ROAD INSTRUCTIONS STEP 14

STEP 16

Template Name: OM_1_col Template Date: 1994_04_29

CP99D009

Make sure that the 4 wheel drive is disengaged and then press the switch to turn on the rotating beacons.

CK99E002

Press the brake pedals down and release the parking brake.

STEP 17

STEP 15

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CP99D002 CP99E003

Press the clutch transmission dump button and then place the gear change lever in third or fourth gear. Release the button.

Move the direction of travel control lever forwards.

NOTE : (Specific to certain countries), there is no fourth gear.

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JOB SITE AND ROAD INSTRUCTIONS

!

WARNING : Check all gauges and indicator/warning lamps frequently.

!

WARNING : Never use the differential lock pedal.

CK99D004

Template Name: OM_1_col Template Date: 1994_04_29

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

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IMPORTANT : In the event of a brake system failure, immediately engage the parking brake.

STEP 18

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JOB SITE AND ROAD INSTRUCTIONS

JOB SITE TRAVEL 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.

STEP 5

STEP 1

CP99D002

Make sure that the direction of travel control lever is in the neutral position and start the engine.

CK99E002

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Make sure that the engine throttle lever is in the low idle position.

STEP 2 Make sure the stabilizers are completely raised.

STEP 6 Raise the loader attachment about 20 cm (8 inch) off the ground.

STEP 7

STEP 3

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Make sure that the doors are closed correctly and that the engine bonnet is fastened.

STEP 4

CP99E003

Press down the transmission dump button and then place the gear change lever in first or second gear.

CK99E007

Adjust the operator’s seat correctly.

Attach the seat belt correctly.

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JOB SITE AND ROAD INSTRUCTIONS

CK99E002

Press the brake pedal down and release the parking brake.

STEP 9

CK99D004

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

!

WARNING : While travelling, check all gauges and indicator/ warning lamps frequently.

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STEP 10

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STEP 8

CP99D002

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

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Template Name: OM_1_col Template Date: 1994_04_29

Place the direction of travel control lever in the desired position, forward or reverse.

JOB SITE AND ROAD INSTRUCTIONS

Template Name: OM_1_col Template Date: 1994_04_29

LOADER ATTACHMENT OPERATING INSTRUCTIONS The instructions contained in this chapter Transmission dump do not cover all possible conditions of use button of the loader attachment. They only constitute basic information to enable the machine to be operated correctly.

NOTE : The first time it is operated, manoeuvre the machine in a clear area, at low speed.

NOTE : To operate the controls, see "Loader attachment controls" in the "Controls/Instruments/Accessories" section.

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!

WARNING : Automatic loader bucket levelling only operates when raising the attachment; it does not operate when lowering the attachment. You must take care to keep the bucket level during attachment lowering to avoid the load being dumped.

CK99E011

To give maximum power to the loader bucket cylinders, press the button and h o ld it d o w n . T h i s w il l c a u s e t h e transmission to revert to neutral.

Release the transmission dump button to engage the transmission once more.

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IMPORTANT : The machine will free wheel when the button is pressed. If necessary, use the brakes to stop the machine.

Safety instructions - Be careful.

- Make sure that the operator’s seat is correctly adjusted in the loader attachment position.

Standard bucket level indicator

- Use the seat belt.

- Make sure that no other person is in the working range of the machine.

CK98G003

Located on the bucket cylinder, this indicator enables the loader bucket to be position ed fla t wh en the p oin te r is opposite the red pointer.

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NOTE : Ensure lifting or handling weight does not exceed 1000 kg (2204 lbs).

Loader bucket configuration

CD98F040

Dozer blade configuration

CD98F042

Clamshell configuration

CD98F041

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CD98F043

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Scraper position

Template Name: OM_1_col Template Date: 1994_04_29

NOTE : Raise the attachment so that the bucket is about 20 cm (8 inch) above the ground.

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7 in 1 loader bucket (if equipped)

JOB SITE AND ROAD INSTRUCTIONS

Load handling configuration

Load lifting configuration

Template Name: OM_1_col Template Date: 1994_04_29

CS98N502

CS98N503

7 in 1 loader bucket clam opening indicator (if equipped) TRIM THIS EDGE

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CK98G008

Located on the cylinders of the clam, this indicator enables the clam opening and depth of penetration of the bucket to be selected when th e b ucke t is in the scraper configuration.

CD98F042

Clam closed.

CD98F040

Clam opening.

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1

!

WARNING : Operating the loader attachment with a full bucket on sloping ground can cause the machine to turn over.

If possible avoid turning the steering wheel and always travel forwards when climbing a slope and in reverse when travelling down a slope. Keep the bucket as close as possible to the ground. There is a risk of accident if these instructions are not observed.

!

WARNING : On the job site, always keep the bucket as close as possible to the ground so as to increase the machine’s stability to the maximum and to ensure perfect visibility.

!

WARNING : On rough or slippery ground, when the bucket is full, drive the machine as slowly as possible. If these instructions are not observed there is a risk of accident.

CK99E010

Place the control lever in position (1). The bucket will tilt backwards until the bottom of the bucket is level, then it will stop. The attachment at the same time continues to lower until the bucket touches the ground or until the control lever is released.

Organising the job site

Heaped material CS95M227

Use the shortest possible work cycle. The location provided for the trucks is an all important element. Spend a little time levelling the work area.

Using the indicator, check that the bottom of the bucket is in the horizontal position.

Drive the machine into the heap of material. When the speed of the machine starts to decrease, raise the attachment and tip the bucket backwards.

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Template Name: OM_1_col Template Date: 1994_04_29

After dumping the load, use this function to bring the bucket back into digging position and to renew the digging cycle automatically.

A smooth working surface facilitates the work of the machine and moving and parking the trucks. It gives a shorter work cycle.

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Return-to-dig

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JOB SITE AND ROAD INSTRUCTIONS

JOB SITE AND ROAD INSTRUCTIONS

BACKHOE ATTACHMENT OPERATING INSTRUCTIONS Template Name: OM_1_col Template Date: 1994_04_29

The instructions contained in this chapter do not cover all possible conditions of operation for the backhoe attachment. They only constitute basic information to enable the machine to be operated correctly.

NOTE : The first time it is operated, manoeuvre the machine in a clear area, at low speed.

NOTE : For the operation of the controls, see "Backhoe attachment controls" in the "Controls/Instruments/Accessories" section.

Safety instructions - Be careful.

- Make sure that the operator’s seat is correctly adjusted in the backhoe attachment position.

- Use the seat belt.

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- Make sure that no other person is in the working range of the machine.

- Place the attachment in the working position. See “Setting the machine in the backhoe attachment working position” in the “Operating instructions” section.

- Never dig near or under the stabilizers, since the machine could fall into the excavation.

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- When working in an area of reduced visibility, for example next to a building, place a safety barrier and sign panels to prevent anyone coming near the machine.

General The backhoe attachment will dig more quickly if the work cycle is short and uninterrupted. Organize your work site so as to obtain a smooth work cycle.

If you try to take a very big cut with the backhoe bucket, you may cause a hydraulic stall situation (where the dipper control lever is pulled towards the operator but nothing happens). The hydraulic system main relief valve makes a noise when a hydraulic stall occurs. This overload causes the work cycle to be prolonged and it increases the hydraulic temperature.

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JOB SITE AND ROAD INSTRUCTIONS

1.

Make sure that the front wheels are straight.

2.

Set the engine speed to 1000 rpm.

3.

Release the machine’s brakes by means of the parking brake.

4.

Make sure that the direction of travel and gear change levers are both in the neutral position.

5.

Raise the boom and retract the dipper, then move the boom so as to place the backhoe bucket teeth on stable ground.

6.

Raise the stabilizers and the loader bucket about 20 cm (8 inch) from the ground.

7.

Use the boom and dipper to move the machine.

8.

After moving the machine, lower the stabilizers and place the loader bucket on the ground, then level the machine.

9.

Use the parking brake to brake the machine.

IMPORTANT : This procedure can only be used on flat ground. Never use it on sloping ground. On sloping ground it is essential to turn the operator’s seat to the loader attachment position to move the machine by the normal procedure.

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It is possible to use the backhoe attachment to push the machine forward whilst excavating.

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Moving the machine forwards when working on flat ground

Fill the backhoe bucket by manoeuvring the boom and dipper. Keep the bottom of the backhoe bucket parallel to the cut. The backhoe bucket teeth and blade must cut the ground like the blade of a knife. The depth of dig varies depending on the type of material.

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Template Name: OM_1_col Template Date: 1994_04_29

Filling the backhoe bucket

JOB SITE AND ROAD INSTRUCTIONS

Excavating method Template Name: OM_1_col Template Date: 1994_04_29

PDH0493M

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PDH0494M

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CORRECT

WRONG

WRONG

The backhoe bucket will dig in and cause a stall.

The bucket is pushed upwards. This will also increase the cycle time.

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SERVICING INTERVALS

!

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.

!

WARNING : If the attachment is raised 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 a flat, level ground.

2. Lower the loader and backhoe attachments until they are resting on the ground.

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

4. Engage the parking brake.

5. Lock the loader attachment controls.

6. Block the wheels to prevent any machine movement.

For all service work on the engine, install the loader attachment support strut.

!

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

When performing maintenance work 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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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.

Template Name: OM_1_col Template Date: 1994_04_29

Observe the servicing intervals by the checking the hourmeter every day. Before starting maintenance, park the machine on flat, firm ground, away from any obstacles, with the loader bucket and the backhoe bucket on the ground. All maintenance operations must be carried out with the engine stopped and the key removed from the starter switch. It is preferable to wait for all circuits to cool down before starting work.

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SERVICING INSTRUCTIONS

SERVICING INTERVALS IMPORTANT : If you use your machine under particularly severe conditions (dusty or corrosive atmosphere, etc.) reduce the interval between servicing operations.

Template Name: OM_1_col Template Date: 1994_04_29

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 down a drain. Stock the oil in sealed containers for collection by a company which recycles or disposes of it.

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

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

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

CD98F031

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LEFT PAGE

SERVICING INTERVALS

201 206 186 187 207 220 230 239 241 187 202 202 205 210 235 235 235 236 242 245 248 248 256 258

O F

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P O I N T S 2 2 2 14 4 23

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10 10 10 50 50 50 50 50 50 50 250 250 250 250 250 250 250 250 250 250 250 250 250 250 250

Template Name: OM_1_col Template Date: 1994_04_29

194

SERVICE POINTS Front axle pivots Front axle steering cylinder Rear axle steering cylinder Loader attachment pivots 7 in 1 loader bucket (NOTE 1) Backhoe attachment pivots (Sideshift (offset) backhoe) Backhoe attachment pivots (Centremount (axial) backhoe) Engine oil level Engine coolant level Rear cardan shaft joints Front cardan shaft joints Radiator level Hydraulic fluid level Transmission oil level (NOTE 2) Brake fluid level Tyres pressure Pedal pivots Engine oil Engine oil filter Cooling system hoses and hose clamp tightness Fuel filter Front drive axle oil level Reduction gear oil level (NOTE 2) Rear axle oil level Front and rear axle breathers Wheel nut torque setting (NOTE 2) Engine alternator and fan belt (NOTE 2) Compressor lubrication (NOTE 1) Compressor drive belt (NOTE 1) ROPS/FOPS cab Steering system fasteners, ball joints and pivots

INTERVALS IN HOURS

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P A G E 186 186 186 188 189 190

N O .

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INTERVALS

SERVICING INTERVALS

Template Name: OM_1_col Template Date: 1994_04_29

P A G E 258 258 259

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213 232 250 281 281 221 222

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223 226 231 233 237 237 240 246 246 280 280 208 252 254 259 260 212 214 215 216 225 226 227

SERVICE POINTS Power steering system pipes, hose and unions Cardan shaft fasteners (NOTE 2) Transmission mounting bolt torque (NOTE 2) Gauze strainer in the fuel lift pump Transmission pressure filter (NOTE 2) Air intake filter cab heater Loader harness Steering harness Hydraulic fluid return filter (NOTE 2) Intake strainer of hydraulic fluid (NOTE 2) Hydraulic fluid Air filter primary element Transmission oil (NOTE 2) Transmission suction strainer (NOTE 2) Front and rear axles oil (NOTE 2) Front reduction gear oil (NOTE 2) Brake fluid Engine valve tip clearances (NOTE 2) Machine inspection and cleaning Alternator Starter motor Engine coolant Parking brake Brake Fuel injectors Turbo-charger Bleeding the fuel system Primary water separator Fuel filter Fuel tank Air intake system (NOTE 2) Air filter secondary element Air filter primary element (NOTE 2)

N O .

INTERVALS IN HOURS

O F

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A

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K 250

E

N

8 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1

250 250 500 500 500 500 500 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 2000 2000 2000 2000 2000 (1) (1) (1) (1) (1) (1) (1)

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G

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SERVICE POINTS Radiator and oil cooler External bearing pads on extendable dipper (NOTE 1) Bucket tooth tightening torque

N O .

INTERVALS IN HOURS

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N (1)

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(1)

-

(1)

NOTE 1 : If equipped.

NOTE 2 : After the first 50 hours during the running-in period.

Template Name: OM_1_col Template Date: 1994_04_29

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(1) As required

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SERVICING INTERVALS

181

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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 mandatory to observe the instructions for use of the various fluids and lubricants.

Hydraulic fluid

Grease

Hydraulic fluid is specially designed for high pressure applications and for hydraulic system. The type of fluid to be used depends upon the ambient temperature.

The type of grease to be used depends on the ambient temperature.

Temperate climates

-5°C to +55°C Extreme pressure grease EP NLGI grade 2 with molybdenum disulphide.

Below 30°C (86°F) Fluid type : ISO VG 46

Temperate and hot climates

Cold climates

Hot climates TRIM THIS EDGE

30°C (86°F) and over Fluid type : ISO VG 68

-20°C to +30°C Extreme pressure grease EP NLGI grade 0.

Brake fluid

Front and rear axles oil

Fluid type : LHM brake fluid

Type of oil to be used : API GL5 grade EP 85W140

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Transmission component oil Extreme pressure oil is used for all cased transmission components.

Extreme pressure oil type API CD/SE grade 10W30.

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Temperate climates

The engine oil to be used depends on the ambient temperature.

-15°C to +30°C (5°F to 86°F) Oil type SAE 10W30

Use only oil of the API/CD category.

Hot climates

NOTE : Do not put any performance additive or other additive in the sump.

Oil change intervals shown in this manual are based on tests carried out on lubricants.

30°C (86°F) and over Oil type SAE 20W50

Cold climates Below -15°C (5°F) Oil type SAE 10W

Oil viscosity/oil operating range

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A

B IO36LO

(A) FAHRENHEIT TEMPERATURE

(B) CENTIGRADE TEMPERATURE

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Template Name: OM_1_col Template Date: 1994_04_29

Engine oil

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LUBRICATION/FILTERS/FLUIDS

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 areas where ambient temperatures are over -36°C, use a blend of 50 % ethylene-glycol based anti-freeze.

For areas where temperatures are below -36°C, it is advisable to use a blend of 40 % water and 60 % anti-freeze.

Fuel

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

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

In cold weather, a mixture of fuel no. 1 and no. 2 is temporarily permitted.

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.

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

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.

ENVIRONMENT Before carrying out any maintenance operation on the machine and before disposing of used fluids or lubricants, always think of the environment. Never throw oil or fluid on the ground and never put them in leaky receptacles.

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

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LUBRICATION/FILTERS/FLUIDS

When cleaning plastic windows, the console, the instrument panel, the gauges, etc., avoid the use of petrol, paraffin, paint solvents, etc. Use only water, soap and a soft cloth.

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

FLUID AND LUBRICANT CAPACITIES ENGINE Capacity (including replacing the filter) ..............................10.7 litres (2.9 US gals) COOLING SYSTEM Cooling system capacity ....................................................16,5 litres (4.4 US gals) FUEL SYSTEM Reservoir capacity ...............................................................120 litres (33 US gals)

FRONT AND REAR AXLES Capacity ..................................................................................8 litres (2.2 US gals) REDUCTION GEAR Capacity (each) ......................................................................4.5 litre (1.2 US gals)

Template Name: OM_1_col Template Date: 1994_04_29

TRANSMISSION Total system capacity ............................................................15 litres (4.1 US gals)

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HYDRAULIC SYSTEM Reservoir capacity...............................................................45 litres (12.4 US gals)

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PLASTIC AND RESIN PARTS

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LUBRICATION/FILTERS/FLUIDS

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

Tool required - Grease gun (delivered with machine) Use the following grease : EP NLGI grade 2 NOTE : The figures shown in brackets indicate the number of grease points.

Every 10 hours

Every 10 hours

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CD99E005

CK99E021

Front axle pivot ..............................(2)

Rear axle steering cylinder............ (2)

Every 10 hours

Every 50 hours

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CD98G007

Front axle steering cylinder ............(2)

CK98G006

Rear cardan shaft joints ................ (3)

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LUBRICATION/FILTERS/FLUIDS

Pedal pivot Tool required TRIM THIS EDGE

- One oil can Every 250 hours

CK99D004

Pedal pivots .................................. (4)

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Template Name: OM_1_col Template Date: 1994_04_29

CK98G007

Front cardan shaft joints................ (3)

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Every 50 hours

LUBRICATION/FILTERS/FLUIDS

Loader attachment Tool required

Template Name: OM_1_col Template Date: 1994_04_29

- Grease gun (delivered with machine) Use the following grease : EP NLGI grade 2 NOTE : The figures shown in brackets indicate the number of grease points.

1

1

4 2

4

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5

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5

3

CP99D004

Every 10 hours

Every 10 hours

1

2

CP99D007

Beam linkage .................................(2)

CK98F022

Beam cylinder bottom pins ............ (2)

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LUBRICATION/FILTERS/FLUIDS Every 10 hours

Every 10 hours

CD99E006

Beam cylinder top pins .................. (2) Every 10 hours

CK98G008

Clam cylinder tops 7 in 1 bucket (if equipped) ............(2) Every 10 hours

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4

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3

CP98G005

Bucket connecting rods ................. (4) Every 10 hours

5

CP98G006

Bucket linkage............................... (4)

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Template Name: OM_1_col Template Date: 1994_04_29

CK98G008

7 in 1 bucket clam cylinder bottom pins (if equipped) ...................... (2)

LUBRICATION/FILTERS/FLUIDS

Backhoe attachment (sideshift (offset) backhoe version) Template Name: OM_1_col Template Date: 1994_04_29

Tool required - Grease gun (delivered with machine) Use the following grease : EP NLGI grade 2 NOTE : The figures shown in brackets indicate the number of grease points.

7 4

9

5

3 6

1

6

2 TRIM THIS EDGE

10

8 6

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10

10

12

12

11 CK98N001

Every 10 hours

Every 10 hours

1

2

CP98N001

Boom cylinder top pin ....................(1)

CK98M041

Upper swing pin ............................ (1)

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LUBRICATION/FILTERS/FLUIDS Every 10 hours

Every 10 hours

CD99E007

CP98A029

Boom cylinder bottom pin .............. (1)

Bucket linkage ............................... (5)

Every 10 hours

Every 10 hours

7 TRIM THIS EDGE

4

CP98G008

Dipper cylinder bottom pin............. (1)

Dipper cylinder top pin................... (1)

Every 10 hours

Every 10 hours

8

5

CP98A029

Bucket cylinder top pin .................. (1)

CD99E009

Boom/dipper linkage...................... (1)

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Template Name: OM_1_col Template Date: 1994_04_29

CD99E008

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6

3

LUBRICATION/FILTERS/FLUIDS Every 10 hours

Every 10 hours

9

11

Template Name: OM_1_col Template Date: 1994_04_29

CD98F064

CK98M041

Bucket cylinder bottom pin .............(1)

Lower swing pin ............................ (1)

Every 10 hours

Every 10 hours

10

12

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CK98M041

Swing cylinders..............................(6)

CP98A030

Boom bottom pin ........................... (3)

192

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193

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Template Name: OM_1_col Template Date: 1994_04_29

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LUBRICATION/FILTERS/FLUIDS

Backhoe attachment (centremount (axial) backhoe version) Template Name: OM_1_col Template Date: 1994_04_29

Tool required - Grease gun (delivered with machine) Use the following grease : EP NLGI grade 2 NOTE : The figures shown in brackets indicate the number of grease points.

7 3 9

1

13

4 TRIM THIS EDGE

6 8

5

10

2 10

6 12

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6

11

13 CD99E019

Every 10 hours

Every 10 hours

1

2

CD98F066

Boom cylinder top pin ....................(1)

CP98G007

Upper swing pin ............................ (1)

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LUBRICATION/FILTERS/FLUIDS Every 10 hours

Every 10 hours

CD99E007

CP98A029

Boom cylinder bottom pin .............. (1)

Bucket linkage ............................... (5)

Every 10 hours

Every 10 hours

7 TRIM THIS EDGE

4

CP98G008

Dipper cylinder bottom pin............. (1)

Dipper cylinder top pin................... (1)

Every 10 hours

Every 10 hours

5

8

CP98A029

Bucket cylinder top pin .................. (1)

CD99E009

Boom/dipper linkage...................... (1)

195

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Template Name: OM_1_col Template Date: 1994_04_29

CD99E008

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6

3

LUBRICATION/FILTERS/FLUIDS Every 10 hours

Every 10 hours

9

12 16

Template Name: OM_1_col Template Date: 1994_04_29

CD98F064

CD98F065

Bucket cylinder bottom pin .............(1)

Boom bottom pin ........................... (2)

Every 10 hours

Every 10 hours

10 13

13 17

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CP98G007

Swing cylinders..............................(4)

CK99E022

Stabilizer cylinders ........................ (4)

Every 10 hours

15 11

CP98G007

Lower swing pin .............................(1)

196

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197

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Template Name: OM_1_col Template Date: 1994_04_29

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LUBRICATION/FILTERS/FLUIDS

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

Template Name: OM_1_col Template Date: 1994_04_29

Every 50 hours

Every 10 hours

CD98G013

CK98F040

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Engine oil.......................................(1)

Hydraulic reservoir ........................ (1)

Every 10 hours

Every 50 hours

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CK99E023

Engine coolant reservoir ................(1) ETHYLENE GLYCOL and WATER

CK98G014

Radiator ........................................ (1) ETHYLENE GLYCOL and WATER

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LUBRICATION/FILTERS/FLUIDS Every 50 hours

CD98G013

CD99E010

Front drive axle ............................. (1)

Every 50 hours

Every 250 hours

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Transmission oil ............................ (1)

CD99D023

CK99E024

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

Template Name: OM_1_col Template Date: 1994_04_29

Brake fluid reservoir ...................... (1)

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Every 250 hours

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LUBRICATION/FILTERS/FLUIDS Every 250 hours

CD99E011

Template Name: OM_1_col Template Date: 1994_04_29

Reduction gears ............................(2)

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200

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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 50 hours during the running in period) Oil filter replacement ..................................................................... Every 250 hours Type of oil ..................................................................... See "Fluids and lubricants” Oil capacity.........................................................................10.7 litres (2.9 US gals)

Level

STEP 3

STEP 1 Park the machine on flat, level ground.

CK99E025

Unlock the engine bonnet and swing it open.

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STEP 2

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Service specifications

STEP 4 Raise the loader attachment, stop the engine, engage parking brake, remove the starter switch key and install the support strut.

CD98G013

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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Template Name: OM_1_col Template Date: 1994_04_29

CK99E017

LUBRICATION/FILTERS/FLUIDS

Oil change and oil filter replacement

STEP 5

Template Name: OM_1_col Template Date: 1994_04_29

Tools required - One 16 mm (5/8 inch) wrench for hexagonal head bolts - One filter wrench NOTE : Drain the engine when it is still hot. The oil will flow more easily.

A

B

STEP 1

CD98F044

Park the machine on flat, level ground.

STEP 2

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CD98G013

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If the oil level is below the (B) mark, remove the filler cap and add oil up to the (A) mark on the dipstick. Then replace the filler cap.

The level should not be higher than the (A) mark on the dipstick.

CK99E017

Raise the loader attachment, stop the engine, engage parking brake, remove the starter switch key and install the support strut.

STEP 6 Close and lock the engine bonnet.

STEP 7 Remove the support strut and lower the loader attachment.

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LUBRICATION/FILTERS/FLUIDS

CD98K020

Place a receptacle of a suitable capacity under the drain plug from the sump, remove the drain plug and allow the oil to flow out.

CD98G015

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

STEP 6

STEP 7 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.

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

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Apply clean oil to the new filter seal.

STEP 4

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STEP 5

STEP 3

STEP 8

CD98K020

Install the drain plug.

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Template Name: OM_1_col Template Date: 1994_04_29

CK99E025

Unlock the engine bonnet and swing it open.

LUBRICATION/FILTERS/FLUIDS STEP 9

Template Name: OM_1_col Template Date: 1994_04_29

CD98G013

Fill the engine with new oil (10.7 litres (2.9 US gals)).

STEP 10 Run the engine for a few minutes and check for leaks. Then check the level again.

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NOTE : Always wait 15 minutes to allow the oil to return to the engine sump before checking the oil level.

STEP 11 Close and lock the engine bonnet.

STEP 12

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Remove the support strut and lower the loader attachment.

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LUBRICATION/FILTERS/FLUIDS

COOLING SYSTEM

!

WARNING : Boiling engine coolant can spray out if the radiator cap is removed while the system is still hot. To remove the cap : allow the system to cool down, turn the cap to the first notch and wait until there is no more pressure. Then remove the cap.

!

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

Engine coolant

Template Name: OM_1_col Template Date: 1994_04_29

Only put ethylene-glycol engine coolant in the cooling system. Use good quality ethyleneglycol that has a high boiling point, with no additives to prevent leakage. Do not use nonapproved anti-rust additives. Anti-rust additives and ethylene-glycol can mix and work against each other, thereby reducing anti-corrosion protection, forming deposits in the cooling system and causing damage to the cooling system and radiator.

Consult your CASE Dealer for suitable engine coolant.

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Coolant reservoir level check ..................................... Every 10 hours or every day Radiator level check ........................................................................ Every 50 hours Cooling system hose and clamp tightness check ......................... Every 250 hours Draining ................................................................. Every 2000 hours or every year Cooling system capacity ....................................................16,5 litres (4.4 US gals) Thermostat range ....................................................77°C to 82°C (170°F to 180°F) Radiator cap pressure .................................................................0.7 bar (10 lbf/in2)

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Service specifications

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LUBRICATION/FILTERS/FLUIDS

Engine coolant level in coolant reservoir

STEP 4

Template Name: OM_1_col Template Date: 1994_04_29

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

STEP 1 Park the machine on flat, level ground.

STEP 2

CK99E023

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The level in the coolant reservoir should be between the "FULL" and "ADD" marks. If necessary, remove the radiator cap and add coolant to the radiator until the level reaches the "FULL" mark on the coolant reservoir.

CK99E017

Raise the loader attachment, stop the engine, engage parking brake, remove the starter switch key and install the support strut.

IMPORTANT : On no account must the coolant reservoir level be higher than it was the day previously. If it is, check the level in the radiator. See “Radiator level”.

STEP 5 Close and lock the engine bonnet.

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STEP 3

STEP 6 Remove the support strut and lower the loader attachment.

CK99E025

Unlock the engine bonnet and swing it open.

IMPORTANT : Do not remove the radiator cap.

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LUBRICATION/FILTERS/FLUIDS

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

STEP 1 Park the machine on flat, level ground.

STEP 2

CK98G014

!

CK99E017

Raise the loader attachment, stop the engine, engage parking brake, remove the starter switch key and install the support strut.

STEP 3

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

IMPORTANT : If the level in the radiator is low, but full in the coolant reservoir, check for an air leak in the hose connecting the radiator to the coolant reservoir. If the problem persists, consult your CASE Dealer.

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Remove the radiator cap. The engine coolant should be level with the filler orifice. If not, see "Filling".

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STEP 4

STEP 5

STEP 6 Remove the support strut and lower the loader attachment.

CK99E025

Unlock the engine bonnet and swing it open.

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Template Name: OM_1_col Template Date: 1994_04_29

Close and lock the engine bonnet.

LUBRICATION/FILTERS/FLUIDS

Draining the cooling system

STEP 4

Template Name: OM_1_col Template Date: 1994_04_29

Tool required - One flat-headed screwdriver STEP 1 Park the machine on flat, level ground.

STEP 2

CK98G014

Remove the radiator cap.

!

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CK99E017

Raise the loader attachment, stop the engine, engage parking brake, remove the starter switch key and install the support strut.

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

NOTE : Prepare a receptacle with a suitable capacity.

STEP 5

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STEP 3

CK98G015

Release the connection on the radiator bottom hose and allow the engine coolant to flow out.

CK99E025

Unlock the engine bonnet and swing it open.

STEP 6 After the system is completely drained, install the bottom hose.

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LUBRICATION/FILTERS/FLUIDS

Rinse the system through with fresh water, drain again and fill the system as shown below.

NOTE : If you use a detergent solution for rinsing, follow the instructions for preparing the solution. After draining the detergent solution, rinse again with fresh water.

STEP 8 Check the condition of the hoses, connections and the water pump. Make sure that the external surfaces of the engine and the radiator are clean.

Filling

CK99E023

Completely fill the coolant reservoir with engine coolant.

IMPORTANT : Use the correct engine coolant.

Run the engine for a few minutes and then check the level in the coolant reservoir again. Top up if necessary until the "FULL" mark is reached. Then install the cap.

IMPORTANT : Do not remove the radiator cap to check the level.

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STEP 3

STEP 1

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STEP 2

STEP 7

STEP 4 Close and lock the engine bonnet.

Fill the radiator with engine coolant until it is level with the filler orifice. Then install the cap.

Remove the support strut and lower the loader attachment.

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Template Name: OM_1_col Template Date: 1994_04_29

STEP 5 CK98G014

LUBRICATION/FILTERS/FLUIDS

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

Fuel filter replacement .................................................................. Every 250 hours (After the first 50 hours during the running-in period) Clean the gauge strainer in the fuel lift pump ............................... Every 500 hours Drain primary water separator............................................................... As required Fuel filter sediment removal .................................................................. As required Fuel tank sediment removal .................................................................. As required Fuel tank capacity ................................................................ 120 litres (33 US gals) Type of fuel ...................................................................See "Fluids and lubricants”

Replacing the filter

STEP 2

Tool required - One 17 mm (21/32 inch) wrench for hexagonal head bolts

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STEP 1

CK99E025

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Unlock the engine bonnet and swing it open.

STEP 3 CK99E017

Raise the loader attachment, stop the engine, engage parking brake, remove the starter switch key and install the support strut.

CK98G013

Place a receptacle of a suitable capacity under the filter, manually unscrew the tap located under the filter and allow the fuel to flow out. Then retighten the plug.

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LUBRICATION/FILTERS/FLUIDS STEP 4

STEP 6

1

2

2 3

3

CK98G013

Remove the bolt (1), the filter cartridge (2) and thoroughly clean the glass bowl (3).

STEP 5

CK98G013

Install the new filter cartridge (2), the glass bowl (3) and the bolt (1). Tighten the bolt.

STEP 7 Vent the fuel system. See “Bleeding the system”.

STEP 8 Close and lock the engine bonnet.

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IMPORTANT : Overtightening of bolt can damage the seal and the filter.

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1

STEP 9 Remove the support strut and lower the loader attachment.

NOTE : Do not fill the new filter with fuel before installing it.

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Template Name: OM_1_col Template Date: 1994_04_29

PH08325

Apply a fine layer of oil or grease on the new filter seal.

LUBRICATION/FILTERS/FLUIDS

Bleeding the system

STEP 3

Tool required

Template Name: OM_1_col Template Date: 1994_04_29

- One 11 mm (7/16 inch) wrench for hexagonal head bolts It is necessary to bleed the fuel system when : - The tank has been completely emptied.

- Parts of the fuel system have been removed for servicing or repair work.

- The machine has been in storage for a fairly long period.

STEP 1

CD98G035

Operate the fuel lift pump’s, priming lever for approximately two minutes.

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NOTE : If the drive cam of the fuel lift pump is at the point of maximum lift, it will not be possible to operate the priming lever. In this case, turn the engine crankshaft one revolution.

STEP 4

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CK99E017

Raise the loader attachment, stop the engine, engage parking brake, remove the starter switch key and install the support strut.

STEP 2 CD98G036

Slacken the fuel pipe union at the thermostart unit.

CK99E025

Unlock the engine bonnet and swing it open.

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LUBRICATION/FILTERS/FLUIDS

Clean the gauze strainer

STEP 5

- One flat-headed screwdriver STEP 1

CD98G035

Operate the priming lever until fuel flows out with no air bubbles in it and then tighten the union.

STEP 6 Operate the starter motor until the engine starts.

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

Wait 2 minutes before recommencing.

STEP 2

STEP 7

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CK99E017

Raise the loader attachment, stop the engine, engage parking brake, remove the starter switch key and install the safety strut.

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Tool required

Close and lock the engine bonnet.

STEP 8

CK99E025

Unlock the engine bonnet and swing it open.

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Template Name: OM_1_col Template Date: 1994_04_29

Remove the support strut and lower the loader attachment.

LUBRICATION/FILTERS/FLUIDS

Bleeding the primary water separator

STEP 3

Template Name: OM_1_col Template Date: 1994_04_29

1

Tool required - One 19 mm (3/4 inch) wrench for hexagonal head bolts

2

STEP 1

3 CS98C183

Remove the cover (1), the seal (2) and the gauze strainer (3).

STEP 4

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Wash the strainer and clean any sediment from the lift pump body.

CK99E017

STEP 5

Raise the loader attachment, stop the engine, engage parking brake, remove the starter switch key and install the safety strut.

1

STEP 2

2

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3 CS98C183

Install the gauze strainer (3), the seal (2) and the cover (1).

STEP 6 Vent the fuel system. See “Bleeding the system”.

CK99E025

Unlock the engine bonnet and swing it open.

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LUBRICATION/FILTERS/FLUIDS STEP 3

Vent the fuel system. See “Bleeding the system”.

Bleeding the fuel filter STEP 1

CD99E012

Remove the plug.

STEP 4

STEP 2

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CK99E017

Raise the loader attachment, stop the engine, engage parking brake, remove the starter switch key and install the safety strut.

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STEP 6

STEP 5

CK99E025

Unlock the engine bonnet and swing it open.

2 1

CD99E012

Retighten the tap (1) and install the plug (2).

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Template Name: OM_1_col Template Date: 1994_04_29

CD99E012

Place a receptacle of a suitable capacity under the tap of the primary water separator, open the tap and allow the soiled fuel to flow out.

LUBRICATION/FILTERS/FLUIDS

Fuel tank sediment removal

STEP 3

Template Name: OM_1_col Template Date: 1994_04_29

Tool required - One 27 mm (13/32 inch) wrench for hexagonal head bolts

CK98G013

Place a receptacle of a suitable capacity under the filter, manually unscrew the plug located under the filter one or two turns.

STEP 4

CD98K009

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Place a receptacle of a suitable capacity under the fuel tank, unscrew the bleed plug located behind the fuel tank one or two turns and allow the soiled fuel to flow out. Then retighten the plug.

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CD98G035

Operate the priming lever, purge the soiled fuel and retighten the plug.

STEP 5 Vent the fuel system. See “Bleeding the system”.

STEP 6 Close and lock the engine bonnet.

STEP 7 Remove the support strut and lower the loader attachment.

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LUBRICATION/FILTERS/FLUIDS

595SLE type Prior to carrying out any service operation on the hydraulic system, it is first necessary to release the pressure in all the circuits.

Before doing this, make sure that the ride control function (optional) is not operating.

STEP 4

STEP 1 Lower the loader attachment and the backhoe attachment until they are resting on the ground.

STEP 2 Stop the engine, engage parking brake.

CP98F024

Operate the backhoe attachment controls in all directions.

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STEP 3

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RELEASING THE PRESSURE IN THE HYDRAULIC SYSTEM

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Template Name: OM_1_col Template Date: 1994_04_29

CD99E021

Turn the starter switch key to “On” position and press the hydraulic enable switch to enable the system. Place the loader control lever in float position, then operate the lever from left to right several times to release the hydraulic pressure.

LUBRICATION/FILTERS/FLUIDS

595LSP type Template Name: OM_1_col Template Date: 1994_04_29

Prior to carrying out any service operation on the hydraulic system, it is first necessary to release the pressure in all the circuits.

Before doing this, make sure that the ride control function (optional) is not operating.

STEP 4

STEP 1 Lower the loader attachment and the backhoe attachment until they are resting on the ground.

STEP 2 Stop the engine, engage parking brake.

STEP 3

CK99E013

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Press the loader or backhoe attachment selector button to obtain control of the attachment behind the operator’s seat.

NOTE : Depending on the position of the seat, this will either be the loader attachment or the backhoe.

CP99D009

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Turn the starter switch key to “On” position and press the hydraulic enable switch.

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LUBRICATION/FILTERS/FLUIDS

Push the right-hand control lever forwards and hold it in that position, at the same time moving the lever from left to right.

CK99E010

Place the loader control lever in float position, then operate the lever from left to right several times.

NOTE : If, for some reason, there is no electrical current, operate the attachments manually (See “Manual operation of the loader arms” and “Manual operation of the backhoe attachment” in the “Operating instructions” Section.

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With backhoe attachment

CP99E004

Non -EC configuration Push the left-hand control lever forwards and hold it in that position. Pull the righthand control lever rearwards and hold it in that position, at the same time moving the lever from left to right.

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Template Name: OM_1_col Template Date: 1994_04_29

Pull the left-hand control lever rearwards and hold it in that position.

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EC configuration

STEP 5 With loader attachment

LUBRICATION/FILTERS/FLUIDS

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

Hydraulic reservoir level check ................................ Every 50 hours or every week Hydraulic fluid return filter replacement .........................................Every 1000 hours or when the warning light on the instrument panel comes on (after the first 50 hours during the running-in period) Draining the circuit ...................................................................... Every 1000 hours Cleaning the intake strainer ........................................................ Every 1000 hours Reservoir capacity .............................................................. 45 litres (12.4 US gals) Type of fluid...................................................................See "Fluids and lubricants”

Reservoir level

STEP 5

STEP 1 Park the machine on flat, level ground.

STEP 2

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Lower the loader bucket flat on the ground.

STEP 3

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Make sure that the backhoe attachment is in the road travel position. See "Setting the backhoe attachment in the road travel position" in the "Operating instructions" Section.

STEP 4

CK98F040

The fluid level should be in the middle of the sight gauge. Top up if necessary. See "Filling".

Stop the engine, engage parking brake, remove the starter switch key and wait until the fluid reaches ambient temperature.

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LUBRICATION/FILTERS/FLUIDS

Replacing the hydraulic fluid return filter Tools required - One filter wrench - One oil can STEP 1 Place the loader bucket resting on the ground, engage parking brake, stop the engine and remove the starter switch key.

STEP 2

CK99E023

IMPORTANT : Do not use the filter wrench to tighten. Overtightening can damage the seal and the filter.

STEP 6

CK99E023

Clean around the filter head.

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

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STEP 5

Place a receptacle of a suitable capacity under the filter, loosen the filter by means of the filter wrench and then unscrew it by hand.

STEP 4 CS98G565

Apply a thin layer of oil on the new filter seal.

Start the engine, run it at low idle speed and make sure that the filter restriction warning light on the instrument panel is not on.

NOTE : After using the machine, check that there are no leaks.

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Template Name: OM_1_col Template Date: 1994_04_29

STEP 3

LUBRICATION/FILTERS/FLUIDS

Cleaning the intake strainer

STEP 4

Template Name: OM_1_col Template Date: 1994_04_29

Tool required - One 13 mm (1/2 inch) wrench for hexagonal head bolts STEP 1 Place the loader bucket resting on the ground, engage parking brake, stop the engine and remove the starter switch key.

STEP 2

CS98G560

Remove by hand the intake strainer from intake pipe clean and dry it.

STEP 5

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CK98F023

Clean around the filler tube.

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STEP 3 CS98G560

Refit and tighten by hand, careful to avoid straining the pleats.

2 1

CK98F023

Remove the bolts (1) securing the filler tube (2) and remove it.

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LUBRICATION/FILTERS/FLUIDS STEP 6

Make sure that the backhoe attachment is in the road travel position. See "Setting the backhoe attachment in the road travel position" in the "Operating instructions" section. Engage parking brake, stop the engine and remove the starter switch key.

STEP 4

CS98G560

Renew the gasket if necessary and fit the filler tube.

CS98G560

Place a receptacle of about 45 litres (12.4 US gals) capacity under the reservoir and remove the filler cap and the drain plug.

Allow the fluid to flow out.

STEP 5

Draining Tool required - One 27 mm (13/32 inch) wrench for hexagonal head bolts NOTE : When carrying out draining, the hydraulic fluid must be at operating temperature.

STEP 1

Drain the other components by removing the supply and return unions. Consult your CASE Dealer.

STEP 6 Install the reservoir drain plug.

NOTE : See "Replacing the hydraulic fluid filter" if the filter has to be replaced.

Park the machine on flat, level ground.

STEP 2 Lower the loader bucket flat on the ground.

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Template Name: OM_1_col Template Date: 1994_04_29

Replacing the hydraulic fluid requires the fluid to be systematically drained from the main components (reservoir, pumps, cylinders, control valves, hydraulic motors and oil cooler).

We recommend you to consult your CASE Dealer.

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Replacing the hydraulic fluid

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STEP 3

LUBRICATION/FILTERS/FLUIDS

Template Name: OM_1_col Template Date: 1994_04_29

Filling

STEP 10

STEP 7

Start the engine and operate the loader attachment and backhoe attachment functions for 3 to 4 minutes.

STEP 11 Once again place the loader bucket flat on the ground and the backhoe attachment in the road travel position. Stop the engine, engage parking brake and remove the starter switch key.

STEP 12 CK98F023

Clean around the filler cap and fill the reservoir with the correct hydraulic fluid.

STEP 8

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CK98F040

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Check the level. The fluid level should come up to the middle of the gauge. Top up if necessary.

CK98F040

The fluid level should be in the middle of the sight glass.

STEP 9

Hydraulic pump If the flow of hydraulic fluid at the pump has been interrupted when hydraulic fluid has been replaced or when the pump has been replaced or if a pipe has burst, it is necessary to service the pump. Consult your CASE Dealer.

CK98F023

Install the filler cap.

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LUBRICATION/FILTERS/FLUIDS

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

The large outer primary element can be cleaned. The smaller inner secondary element can not be cleaned and should be replaced.

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PH00622

Your machine is fitted with a two-stage air filtering system, consisting of a high capacity primary element, designed to provide optimal protection of the engine, plus a secondary element which provides extra engine protection.

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Inspection

AIR FILTER Air filter elements

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Template Name: OM_1_col Template Date: 1994_04_29

CS98G565

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

LUBRICATION/FILTERS/FLUIDS

Service specifications Template Name: OM_1_col Template Date: 1994_04_29

Primary element maintenance ...................................................... Clean or replace When the warning lamp on the instrument panel comes on (After the first 50 hours during the running-in period) Primary element replacement ................... Every 1000 hours or after six cleanings Secondary element replacement ......................................................... Once a year or after cleaning the primary element three times IMPORTANT : Carefully observe the air filter service intervals. The life of the engine depends on the cleanliness of the air filter.

Removing the elements

STEP 2

STEP 1

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CK99E025 CK99E017

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Raise the loader attachment, stop the engine, engage parking brake, remove the starter switch key and install the support strut.

Unlock the engine bonnet and swing it open.

STEP 3

CD98G034

Undo the quick release clips holding the cover and remove it.

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LUBRICATION/FILTERS/FLUIDS

Tool required - A compressed air line

CD98G032

Carefully remove the primary element.

STEP 5 PE08311

Blow compressed air from the inside towards the outside at very low pressure.

The compressed air nozzle should be held at least three centimetres from the inside wall of the primary element. Cleaning is completed once no more dust comes out of the primary element.

IMPORTANT : The secondary element must not be cleaned. It must be replaced every year or after three cleanings of the primary element.

IMPORTANT : Make sure you protect your face before using compressed air.

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

IMPORTANT : Compressed air pressure should not exceed 7 bar (101lbf/in2).

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

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Template Name: OM_1_col Template Date: 1994_04_29

CD98G033

If the secondary element has to be replaced, take care whilst removing.

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If the primary element is dry :

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Cleaning the primary element

STEP 4

LUBRICATION/FILTERS/FLUIDS

Installing the elements STEP 1

Template Name: OM_1_col Template Date: 1994_04_29

Clean the inside of the filter body by means of a clean cloth.

STEP 2

PDE0088

If the primary element is oily : Clean it in water with a suitable detergent (consult your CASE Dealer). Instructions for using the detergent are printed on the packaging.

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The primary element must be completely dry before installing. We advise you to keep a spare, clean primary element for installation while the other primary element is drying.

CD98G033

Carefully install a secondary element if the old element had to be replaced.

STEP 3

Inspecting the primary element

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Tool required - An inspection lamp Check the primary element for damage by placing an inspection lamp inside.

IMPORTANT : Replace the element if light can be seen through a hole, however small.

CD98G032

Carefully install the primary element.

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LUBRICATION/FILTERS/FLUIDS STEP 6

STEP 4

STEP 7 Remove the support strut and lower the loader attachment.

CD98G034

Install the cover and fasten the quick release clips.

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STEP 5

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Close and lock the engine bonnet.

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Template Name: OM_1_col Template Date: 1994_04_29

CS98G565

Start the engine, run it at low idle speed and make sure that the filter restriction warning light on the instrument panel is not on.

LUBRICATION/FILTERS/FLUIDS

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

Oil level check ................................................................................. Every 50 hours (After the first 50 hours during the running-in period) Filter replacement ......................................................................... Every 500 hours (After the first 50 hours during the running-in period) Cleaning the screen filter ............................................................ Every 1000 hours (After the first 50 hours during the running-in period) Oil change ................................................................................... Every 1000 hours (After the first 50 hours during the running-in period) Total system capacity ............................................................ 15 litres (4.1 US gals) Type of oil......................................................................See "Fluids and lubricants”

Level

STEP 3

STEP 1 Park the machine on flat, level ground.

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STEP 2

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CK99E025

Unlock the engine bonnet and swing it open.

CK99E017

Raise the loader attachment, stop the engine, engage parking brake, remove the starter switch key and install the support strut.

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LUBRICATION/FILTERS/FLUIDS

Draining

STEP 4

- One 17 mm (21/32 inch) wrench for hexagonal head bolts STEP 1

CK98G013

Remove the dipstick, clean it with a clean cloth and replace it in the guide tube up to the stop. Then remove it again.

STEP 5

STEP 2

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CK99E017

Raise the loader attachment, stop the engine, engage parking brake, remove the starter switch key and install the support strut.

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Tool required

STEP 6 Close and lock the engine bonnet.

STEP 7

CK99E025

Remove the support strut and lower the loader attachment.

Unlock the engine bonnet and swing it open.

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Template Name: OM_1_col Template Date: 1994_04_29

CD98F044

If the oil level is below the mark, top up.

See "Filling”.

LUBRICATION/FILTERS/FLUIDS

Replacing the filter

STEP 3

Tools required

Template Name: OM_1_col Template Date: 1994_04_29

- One filter wrench - One 13 mm (1/2 inch) wrench for hexagonal head bolts - One oil can STEP 6

CK98G001

Place a receptacle of a capacity of about 15 litres (4.1 US gals) under the drain plug and remove the drain plug.

STEP 4

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CD98G031

Remove the access panel in the cab.

STEP 7

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CK98G013

Remove the filler cap and allow the oil to flow out.

STEP 5 Install the drain plug and the filler cap.

CD98G030

Clean around the filter head.

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LUBRICATION/FILTERS/FLUIDS STEP 8

Cleaning the screen filter STEP 11

STEP 9 Apply a thin layer of oil on the new filter seal.

STEP 10

CD98G030

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

Dry the screen filter carefully compressed air and install it.

with

IMPORTANT : Make sure you protect your face before using compressed air.

Install the cover plate.

Template Name: OM_1_col Template Date: 1994_04_29

IMPORTANT : Do not use the filter wrench to tighten. Overtightening can damage the seal and the filter.

IMPORTANT : Follow the instructions for the detergent solution.

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CD99E013

Clean around the cover plate and remove it. Check the condition of the O-ring and replace it if necessary. Remove the screen filter and clean it in a detergent solution.

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Place a receptacle of a suitable capacity under the filter, loosen the filter by means of the filter wrench and then unscrew it by hand.

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LUBRICATION/FILTERS/FLUIDS

Filling

STEP 16

STEP 12

Template Name: OM_1_col Template Date: 1994_04_29

CD98G031

Replace the access panel.

CK98G013

Remove the filler cap and fill with the correct oil to the oil level mark on the dipstick. Then replace the filler cap.

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STEP 13

STEP 17 Close and lock the engine bonnet.

STEP 18 Remove the support strut and lower the loader attachment.

Start the engine and check for leaks.

STEP 14 Drive the machine for a few minutes in first and second gear then stop the engine.

STEP 15

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CK98G013

Check the oil level by means of the dipstick. Top up if necessary.

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LUBRICATION/FILTERS/FLUIDS

FRONT AND REAR AXLES AND REDUCTION GEARS Oil level check ............................................................................... Every 250 hours (After the first 50 hours during the running-in period) Cleaning the front and rear axle breathers.................................... Every 250 hours Oil change ................................................................................... Every 1000 hours (After the first 50 hours during the running-in period) Axle oil capacity (4 wheel drive) ..............................................8 litres (2.2 US gals) Reduction gear oil capacity (each) .......................................4.5 litres (0.3 US gals) Type of oil ..................................................................... See "Fluids and lubricants”

Axle oil level

(Rear axle)

Tool required - One 17 mm (21/32 inch) wrench for hexagonal head bolts

Park the machine on flat, level ground, stop the engine, engage parking brake and remove the starter switch key.

STEP 2 (Front axle) CK99E024

Remove the plug and check that the oil is level with the orifice. If necessary, top up via this orifice.

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STEP 1

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Service specifications

Install the plug.

Reduction gear oil level Tool required CD99E010

- One 17 mm (21/32 inch) wrench for hexagonal head bolts STEP 1 Park the machine on flat, level ground.

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Template Name: OM_1_col Template Date: 1994_04_29

STEP 3

LUBRICATION/FILTERS/FLUIDS STEP 6

STEP 2

Template Name: OM_1_col Template Date: 1994_04_29

The oil should be level with the orifice. If necessary, top up via this orifice.

STEP 7 Install the plug.

STEP 8 Repeat Steps 5 to 7 for the other reduction gear.

STEP 9 CD99E016

Make sure that the direction of travel control lever and gear change lever are in neutral position.

STEP 3

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Use the loader attachment to raise the front of the machine slightly so that the front wheels are no longer in contact with the ground and place blocks under the front drive axle. Chock rear wheels.

Lower the machine to the ground.

STEP 10 Use the stabilizers to raise the rear of the machine slightly so that the rear wheels are no longer in contact with the ground and place blocks under the rear axle. Chock front wheels.

STEP 11

STEP 4

Repeat steps 5 to 7 for the two rear reduction gears.

Stop the engine, engage parking brake and remove the starter switch key.

STEP 12

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Lower the machine to the ground.

STEP 5

Cleaning the breather

CD99E011

Manually turn the wheel until the orifice is in the horizontal position and remove the plug.

CK99E024

Check that the front and rear axle breathers are not blocked or damaged.

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LUBRICATION/FILTERS/FLUIDS

Draining and filling the axles

STEP 3

Tools required

STEP 4

- One 11 mm (7/16 inch) wrench for hexagonal socket head bolts - One 17 mm (21/32 inch) wrench for hexagonal head bolts STEP 1

1

Park the machine on flat, level ground, stop the engine, engage parking brake and remove the starter switch key.

STEP 2

CD99E010

Draining and refilling the reduction gears

1

Tool required - One 17 mm (21/32 inch) wrench for hexagonal head bolts CD99E010

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Fill with oil via the filler orifice (1) until the oil is level with the orifice. Then install the plug.

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Install the drain plug.

STEP 1 Park the machine on flat, level ground.

2

CD99E014

Place a receptacle of a capacity of about 8 litres (2.2 US gals) under the plug (2) and remove the plugs (1) and (2). Allow the oil to flow out.

CD99E016

Make sure that the direction of travel control lever and gear change lever are in neutral position.

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Template Name: OM_1_col Template Date: 1994_04_29

STEP 2

LUBRICATION/FILTERS/FLUIDS STEP 3

STEP 7

Template Name: OM_1_col Template Date: 1994_04_29

Use the loader attachment to raise the front of the machine slightly so that the front wheels are no longer in contact with the ground and place blocks under the front drive axle. Chock rear wheels.

STEP 4 Stop the engine, engage parking brake and remove the starter switch key.

STEP 5 CD99E011

Turn the wheel by hand until the orifice is in the horizontal position and then fill via that orifice until the oil is level with the orifice.

STEP 8

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Install the plug.

STEP 9 CD99E015

Repeat Steps 5 to 8 for the other reduction gear.

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Turn the wheel by hand until the orifice is in the lowest position.

STEP 10

STEP 6

Start engine and lower the machine to the ground.

Place a receptacle of about 4.5 litres (1.2 US gals) capacity under the reduction gear, remove the drain plug and allow the oil to flow out.

STEP 11 Use the stabilizers to raise the rear of the machine slightly so that the rear wheels are no longer in contact with the ground and place blocks under the rear axle. Chock front wheels.

STEP 12 Repeat Steps 5 to 8 for the two rear reduction gears.

STEP 13 Start engine and lower the machine to the ground.

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LUBRICATION/FILTERS/FLUIDS

BRAKE FLUID Brake fluid level check .................................................................... Every 50 hours Brake fluid change ...................................................................... Every 1000 hours IMPORTANT : Only use mineral brake fluid to CASE specification.

NOTE : In the absence of an international standard for mineral brake fluids, use one of the following : LHM Brake Fluid part No. 3621 170 M1 Total LHM Fluid Castrol LHM Fluid or CHSMO BP LHM Fluid

Level

STEP 3

STEP 1 TRIM THIS EDGE

Park the machine on flat, level ground.

STEP 2

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Service specification

CK99E025

Unlock the engine bonnet and swing it open.

CK99E017

Raise the loader attachment, stop the engine, engage parking brake, remove the starter switch key and install the support strut.

CD99D023

The level in the brake fluid reservoir should be maintained to the moulded joint on the reservoir.

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Template Name: OM_1_col Template Date: 1994_04_29

STEP 4

LUBRICATION/FILTERS/FLUIDS STEP 5 Ensure breather hole in cap is not blocked.

Template Name: OM_1_col Template Date: 1994_04_29

NOTE : Do not overfill, as spillage from the breather may occur when working on steep gradients.

IMPORTANT : Any sudden loss of fluid must be reported immediately to your CASE Dealer.

STEP 6 Close and lock the engine bonnet.

STEP 7 Remove the support strut and lower the loader attachment.

Draining the brake fluid TRIM THIS EDGE

IMPORTANT : This machine is equipped with hydraulic brakes which must be vented if any part of the brake system has been disconnected. It is important that the following procedure is adopted to ensure satisfactory brake operation.

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This work should be entrusted to your CASE Dealer.

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MAINTENANCE/ADJUSTMENTS

!

WARNING : 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.

!

WARNING : When checking tyre pressures or during an inflation operation, never face the tyre. 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.

Tyre pressures IMPORTANT : Make sure you protect your face before using compressed air.

Pressure check ............................................................................... Every 50 hours Inflation pressure

Dimensions and type

lbf/in2

W15L x 24,16.9 x 24 12P R4 SG

2.2

32

W15Lx24,16.9 14,5P NOKIA

2.8

41

W15Lx 24,16.9R x M27

2.2

32

W15L x 24,17.5LR x M27

1.8

26

Template Name: OM_1_col Template Date: 1994_04_29

Bar

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Service specification

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WHEELS AND TYRES

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MAINTENANCE/ADJUSTMENTS

Wheel nut torque settings Tool required

Template Name: OM_1_col Template Date: 1994_04_29

- A torque wrench

Service specifications Torque tightening check ................................................................ Every 250 hours Every day for five day, after remove a wheel (After the first 50 hours during the running-in period) Front wheel nuts ......................................................................................... 300 Nm Rear wheel nuts ..........................................................................................300 Nm

Replacing a wheel

STEP 7

Tools required - One 30 mm (1.18 inch) wrench for hexagonal head bolts STEP 1

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Park the machine on flat, level ground, with no obstacles in the area.

STEP 2 Loosen the retaining nuts from the wheel which is to be removed.

STEP 3

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Start the engine and use the loader attachment and the stabilizers to lift the machine until the wheels are no longer in contact with the ground.

STEP 4

CP99D004

In stall a new wheel, obse rving th e orientation of the tread pattern.

STEP 8 Install the nuts and tighten them to correct torque, see “Wheel nut torque settings”.

STEP 9

Stop the engine, engage parking brake and remove the starter switch key.

Remove the blocks from under the axle.

STEP 5

STEP 10

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

Lower the machine to the ground.

STEP 6 Remove the nuts and remove the wheel.

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

IMPORTANT : Make sure you protect your face before using compressed air.

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MAINTENANCE/ADJUSTMENTS

The servicing of tyres and wheels for this machine should only be entrusted to a qualified mechanic, who will know how to inflate the tyres while observing safety instructions. To avoid any accident, use a protective device (an inflation cage for tyres), suitable tools and respect 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 the wheel components (a wheel consisting of several parts).

LOADER BUCKET RETURN-TO-DIG ADJUSTMENT

Template Name: OM_1_col Template Date: 1994_04_29

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Loader bucket return to dig is calibrated by CASE prior to the machine being sold.

Consult your CASE Dealer if this needs re-setting.

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Tyre or wheel service

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MAINTENANCE/ADJUSTMENTS

RADIATOR AND OIL COOLER Service specifications Template Name: OM_1_col Template Date: 1994_04_29

Checking for leaks ......................................................Every 10 hours or every day Cleaning ................................................................................................ As required

Cleaning STEP 2

STEP 1

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CK99E017

Raise the loader attachment, stop the engine, engage parking brake, remove the starter switch key and install the support strut.

CK99E023

Clean : Dry dust : use compressed air.

Mud : use a water jet.

Oily dust : use perchlorethylene.

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IMPORTANT : The use trichlorethylene is strictly forbidden.

of

STEP 3 Remove the support strut and lower the loader attachment.

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MAINTENANCE/ADJUSTMENTS

ENGINE ALTERNATOR AND FAN BELT Check ............................................................................................ Every 250 hours (After the first 50 hours during the running-in period)

Inspection

CK99E017

CD98G026

Raise the loader attachment, stop the engine, engage parking brake, remove the starter switch key and install the support strut.

Depress the fan belt by hand. The deflection should be 13 - 19 mm (1/2 - 3/4 inch).

STEP 2

Tool required

Replacement

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STEP 3

STEP 1

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Service specification

- One 13 mm (1/2 inch) wrench for hexagonal head bolts

1 2

CK99E025

Unlock the engine bonnet and swing it open.

CD98G026

Slacken the bolts (1) and (2) and push the alternator. Remove the fan belt.

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Template Name: OM_1_col Template Date: 1994_04_29

STEP 1

MAINTENANCE/ADJUSTMENTS

Template Name: OM_1_col Template Date: 1994_04_29

STEP 2

STEP 4

Install a new fan belt.

Close and lock the engine bonnet.

STEP 3

STEP 5 Remove the support strut and lower the loader attachment.

1 2

CD98G026

Stretch the fan belt and tighten the bolts (1) and (2) and check the deflection.

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ENGINE VALVE TIP CLEARANCE ADJUSTMENT Service specification Inspection.................................................................................... Every 1000 hours (After the first 50 hours during the running-in period) NOTE : Consult your CASE Dealer.

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MACHINE INSPECTION AND CLEANING Service specifications Inspection and cleaning .............................................................. Every 1000 hours Or whenever oil or grease has been spilt on the machine; clean such deposits off with steam or high pressure water.

Take advantage of this operation to make a visual check of all the welded components (possible appearance of cracks), and the attachment linkage. Mark any leaks, check the condition of pipes and hoses.

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MAINTENANCE/ADJUSTMENTS

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.

4.

Check for leaks.

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

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

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CYLINDER LEAK INSPECTION

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AIR CONDITIONING (optional) Template Name: OM_1_col Template Date: 1994_04_29

The air conditioning system components require maintenance at regular intervals.

Observe these intervals to ensure correct operation and full efficiency of the air conditioning. The air conditioning system contains a gas which is subject to strict regulations. Any problem with the system must be resolved quickly.

!

WARNING : Never perform any service operation on the air conditioning circuit. For any operation, consult an approved specialist.

NOTE : Run the air conditioning at least once a week, even for a short time. See "Heating, ventilation and air conditioning" in the "Controls/Instruments/Accessories" section.

Service specifications Compressor lubrication ................................................................. Every 250 hours Compressor drive belt inspection.................................................. Every 250 hours IMPORTANT : Never unscrew the plug located on the top of the compressor since that would discharge the entire circuit.

Compressor lubrication TRIM THIS EDGE

Compressor drive belt inspection Tools required

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- One 17 mm (21/32 inch) wrench for hexagonal head bolts STEP 1 CP98G010

Using the air conditioning controls in the o p e r a t o r ’s c o m p a r t m e n t , r u n t h e compressor so as to lubricate the internal seal. See “Air conditioning controls” in the “Controls/Instruments/Accessories” section.

NOTE : In cold weather, run the engine for a few minutes and then start the compressor.

CK99E017

Raise the loader attachment, stop the engine, engage parking brake, remove the starter switch key and install the support strut.

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Check the drive belt tension. If necessary, adjust the tension. Unscrew the retaining hardware, tighten the drive belt and retighten the hardware. The deflection should be 13 - 19 mm (1/2 - 3/4 inch).

STEP 2

IMPORTANT : The drive belt should not be overtightened (premature bearing wear) or too slack (premature belt wear).

STEP 4 Close and lock the engine bonnet.

CK99E025

Unlock the engine bonnet and swing it open.

Remove the support strut and lower the loader attachment.

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STEP 3

STEP 5

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MAINTENANCE/ADJUSTMENTS

IMPORTANT : After replacing the drive belt, make an adjustment after the first 10 operating hours. s

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Template Name: OM_1_col Template Date: 1994_04_29

CP98G010

Check the condition of the compressor drive belt. Replace it if it is worn or damaged and adjust the tension.

MAINTENANCE/ADJUSTMENTS

AIR INTAKE FILTER CAB HEATER Service specifications Template Name: OM_1_col Template Date: 1994_04_29

Filter cleaning................................................................................ Every 500 hours or in case of reduced air circulation

Tools required

STEP 2

- One cross-headed screwdriver STEP 1

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CK98K010

Remove the filter.

CK98K009

Remove the screw and the cab grille.

STEP 3 Check the condition of the filter. Replace it or clean it if necessary.

STEP 4

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Blow the filter through with compressed air.

IMPORTANT : Make sure you protect your face before using compressed air.

IMPORTANT : The air pressure must be 2 bar maximum.

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STEP 5

STEP 8

Clean the filter in water using a suitable detergent (Consult your CASE Dealer).

Instructions for using the detergent are printed on the packaging.

Clean around the filter housing.

STEP 6

STEP 10

Allow the filter to dry completely.

Install the cab grille and the screw.

STEP 9 Install the new or cleaned filter.

STEP 7 Check the condition of the filter by placing an inspection lamp behind the filter.

Template Name: OM_1_col Template Date: 1994_04_29

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IMPORTANT : The filter must be replaced if light can be seen through a hole, however small.

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MAINTENANCE/ADJUSTMENTS

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PARKING BRAKE INSPECTION AND ADJUSTMENT Service specification Template Name: OM_1_col Template Date: 1994_04_29

Check and adjustment ................................................................ Every 2000 hours STEP 1

STEP 3

CK99E002

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Engage the parking brake and start the engine.

STEP 2

CP99D002

Place the direction of travel control lever in forward drive. The audible warning device will sound.

STEP 4

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CP99E003

Place the gear change lever in third gear.

CK99D004

Using the accelerator pedal, increase the engine speed to about 1800 rpm. The machine must not move. If the machine moves, adjust the parking brake.

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MAINTENANCE/ADJUSTMENTS

Adjustment

STEP 6

Park the machine on flat, level ground, with the loader beams 30 cm above the ground. Make sure that the backhoe boom locking device is engaged.

STEP 2 Use the stabilizers to raise the rear wheels.

3

STEP 3

4 CP98A015

IMPORTANT : Make perfectly sure that the jacks are capable of supporting the weight (8700 kg (3944 lb))

STEP 7 TRIM THIS EDGE

Use workshop jacks to support the rear of the machine, making sure the wheels are not touching the ground.

Make sure that the play between the caliper (3) and the disc (4) has not been reduced.

STEP 4 Lower the loader arms to the ground, stop the engine, remove the starter switch key and release the parking brake.

STEP 5

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STEP 1

4 Apply the parking brake and check that the brake disc (4) engages before the brake lever reaches the seventh notch.

2

STEP 8 Start the engine and raise the loader 30 cm above the ground. Use the stabilizers to raise the rear of the machine.

3 CS97N088

Adjust the brake caliper (3) nuts (2) to take up the play in the cable (1).

STEP 9 Remove the workshop jacks, lower the machine to the ground and stop the engine.

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Template Name: OM_1_col Template Date: 1994_04_29

CP98A015

1

MAINTENANCE/ADJUSTMENTS

BRAKE CHECK Service specification Template Name: OM_1_col Template Date: 1994_04_29

Check .......................................................................................... Every 2000 hours (After the first 50 hours during the running-in period) STEP 4

STEP 1 Park the machine on flat, level ground and engage parking brake.

STEP 2

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CK99D004

Using the accelerator pedal, run the machine at maximum speed.

STEP 5 CP99E003

Place the gear change lever in the second gear.

STEP 3

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CK99D004

CP99D002

Place the direction of travel control lever in the fo rward position. Disengage parking brake.

Press down on the brake pedal. The machine should stop smoothly, in a straight line and the tension on the pedal should remain firm. If not, consult your CASE Dealer.

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MAINTENANCE/ADJUSTMENTS

If it should be necessary to replace the ride control system accumulator, consult your CASE Dealer.

!

WARNING : Use only a dry inert gas such as nitrogen to pre-load the accumulator.

!

WARNING : Release pressure completely in the accumulator before starting any accumulator disassembly operation.

!

WARNING : Never try to carry out any servicing operation on the accumulator to avoid replacing it. If this instruction is not followed serious or fatal injury can result.

Template Name: OM_1_col Template Date: 1994_04_29

!

WARNING : Release pressure completely in the hydraulic system before disconnecting the hydraulic piping. Hydraulic oil escaping under pressure can cause serious injury.

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IMPORTANT : Consult the service manual to obtain complete information on inspecting the accumulator and the solenoid.

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RIDE CONTROL SYSTEM ACCUMULATOR (optional)

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MAINTENANCE/ADJUSTMENTS

ROPS/FOPS CAB Your machine has a ROPS/FOPS cab.

Template Name: OM_1_col Template Date: 1994_04_29

- ROPS : Roll over protective structure.

- FOPS : Falling object protective structure.

An identification plate is attached to the ROPS/FOPS cab. See "ROPS/FOPS cab" in the "Type, serial number and year of manufacture of the machine" section for : - The manufacturer’s address.

- The ROPS/FOPS serial number.

- The reference to the performance requirements meet : ISO 3471/1 1996

Service specifications Inspection...................................................................................... Every 250 hours

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Maintenance and inspection

Damage

Check the torque of the mounting bolts and, if necessary, tighten the bolts to the correct torque.

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Check the operator’s seat and the seat belt mounting hardware. Tighten the bolts to the correct torque. Replace parts showing signs of wear or damage.

Check that there are no cracks, rust or holes in the ROPS/FOPS cab and components. Age, weather and accidents can cause damage. If you have any doubt about the state of the ROPS/FOPS cab, consult your CASE Dealer.

If the machine has rolled over or if the ROPS/FOPS cab has been in some other type of accident, you must replace the damaged ROPS/FOPS components in order to conserve the same degree of protection you had previously.

After an accident, check the following for damage : - The ROPS/FOPS cab.

- The lower ROPS/FOPS cab chassis.

- The operator’s seat.

- The seat belt mounting hardware.

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!

WARNING : Improper ROPS/ FOPS cab inspection or maintenance can cause serious injury.

Carry out the recommended ROPS/FOPS cab inspection procedure shown in this manual. If it is necessary to replace ROPS/FOPS parts or the ROPS/FOPS cab, use only the replacement parts shown in the Parts Catalogue for your machine.

WARNING : Do not try to weld or straighten the ROPS/FOPS cab.

!

WARNING : Do not modify the ROPS/FOPS cab 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 if subjected to roll over or damage.

Do not attempt to repair it.

!

WARNING : If you operate this machine without a ROPS/FOPS cab 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 removed.

Template Name: OM_1_col Template Date: 1994_04_29

!

!

WARNING : Do not install accessories (fixed or otherwise) which may increase the weight of the machine. This may cause serious accidents. Do not exceed the maximum weight shown on the ROPS/FOPS cab identification plate.

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IMPORTANT : Before putting the machine back into service, make sure all the damaged components of the ROPS/ FOPS cab have been replaced. See the Parts Catalogue for your machine or consult your CASE Dealer.

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MAINTENANCE/ADJUSTMENTS

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STEERING AND AXLES Service specifications Template Name: OM_1_col Template Date: 1994_04_29

Check all steering system fasteners and all ball joints and pivots for wear........................................ Every 250 hours Check power steering system pipes, hoses and unions for damage or leakage................................. Every 250 hours Check all cardan shaft fasteners for correct torque ...................... Every 250 hours (After the first 50 hours during the running-in period)

Check all steering system fasteners and all ball joints and pivots for wear

Check all cardan fasteners for correct torque

If wear or excessive play occurs in the steering mechanism contact your CASE Dealer.

Tool required - A torque wrench

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Check power steering system pipes, hoses and unions for damage or leakage

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This machine is equipped with hydrostatic power steering and it is therefore important that hoses are maintained in perfect condition and that no leaks occur anywhere in the steering system. If accessories have been added after the machine was purchased, check to ensure that they do not interfere with steering system hoses or components.

CS99E512

Check tightness of the mounting bolts for the front and rear cardan shafts.

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MAINTENANCE/ADJUSTMENTS

TRANSMISSION Check transmission mounting bolt torques ................................... Every 250 hours (After the first 50 hours during the running-in period)

Tool required - A torque wrench

CS98G562

FUEL INJECTORS Service specification Service the fuel injectors ............................................................. Every 2000 hours

Early signs of atomizer malfunction are : -

Misfiring.

Knocking in one or more cylinders.

Engine overheating.

Loss of power.

Black smoky exhaust.

Increased fuel consumption.

Other faults can cause apparently similar symptoms and should be checked before removing injectors.

- Water in the fuel.

- Wrong fuel.

- Dirty or damaged fuel filters.

If none of these faults are present then call your CASE Dealer.

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Template Name: OM_1_col Template Date: 1994_04_29

Fuel injection atomizers require regular servicing to maintain efficient operation.

This work must be done by a CAV, Perkins Dealer or your CASE Dealer.

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Check the tightness of the eight transmission mounting bolts (four each side of machine).

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Service specification

MAINTENANCE/ADJUSTMENTS

TURBO-CHARGER Service specification Template Name: OM_1_col Template Date: 1994_04_29

Turbo-charger maintenance ........................................................ Every 2000 hours The following items are precautionary measures only, designed to ensure the continued performance of the turbocharger. This work is best entrusted to your CASE Dealer.

Remove and clean the oil drain pipe between the turbo-charger and sump.

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Remove the air inlet duct and compressor housing and check for dirt/carbon deposits which must be cleaned off the compressor wheel with a soft brush. An uneven deposit will unbalance the wheel and cause premature bearing failure. If any deposits are found, the source of the contamination must be traced and corrected.

While the compressor housing is removed, turn the compressor wheel, while pushing on the end of the shaft.

Listen for unusual noises which indicate that either the compressor or turbine wheels are touching the housing. If any such noises are heard, the turbo-charger must be removed and inspected immediately, by your CASE Dealer.

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MAINTENANCE/ADJUSTMENTS

EXTENDABLE DIPPER Replacement of the external bearing pads ........................................... As required

Tool required - One 19 mm (3/4 inch) wrench for hexagonal head bolts

Top and bottom bearing pads

STEP 3

STEP 1

3

NOTE : The bucket must not be resting on the ground - dipper must be supported.

CS98G563

STEP 2

Slide out the old bearing pad (3) and replace it with a new one.

STEP 4

1

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Position the extendable dipper so that the inner member is extended approximately 30 cm (12 inch) and is resting on the bottom bearing pad.

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Service specification

1

4

2

CS98G563

Remove all eight bolts (1) and lift off the top plate (2).

CS98G563

Refit the plate (2), spacers (4) and bolts (1), which should be tightened to 140 Nm (104 lbf ft).

STEP 5 Lower the extendable dipper until the bucket contacts the ground so that the inner extendable member is pressed against the top bearing pad.

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Template Name: OM_1_col Template Date: 1994_04_29

2

MAINTENANCE/ADJUSTMENTS STEP 6

STEP 9

Template Name: OM_1_col Template Date: 1994_04_29

6

5

5

6

CS98G563

CS98G563

Remove three bolts (5) and the retainer plate (6).

Refit the retainer plate (6) and tighten bolts (5) to 140 Nm.

STEP 7

Side wear pads STEP 10

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Raise dipper, bucket must be clear of the ground (dipper must be supported).

STEP 11

7

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8

CS98G563

Remove the bottom bearing pad (7) and shims.

9

STEP 8 Fit a new bearing pad and adjust the shim thickness to give a maximum gap of less than 1 mm.

CS98G563

Remove sixteen bolts (8) and all four housings (9), shims and bearing pads.

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MAINTENANCE/ADJUSTMENTS STEP 12

Fit two new bearing pads into the remaining housings and assemble the housings to the opposite side of the outer member. Fit and partially tighten all eight bolts.

STEP 16 Measure the clearance between the inner member and the bearings pads just fitted.

STEP 17 CS98G563

STEP 13 Fit both housings to one side of the extendable dipper outer member. Fit the bolts and tighten to 60 Nm (45 lbf ft).

Remove the housings fitted in step 15 and add shims behind the bearing pads to achieve a total clearance between the bearing pads and the inner member of less than 1 mm.

STEP 18 Fit and tighten the bolts to 60 Nm (45 lbf ft).

STEP 14

Template Name: OM_1_col Template Date: 1994_04_29

Push the inner member hard against the bearing pads just fitted.

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Place a 1 mm shim, a 2 mm shim and a new bearing pad into two of the housings.

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STEP 15

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MAINTENANCE/ADJUSTMENTS

REPLACING A STABILIZER PAD (centremount (axial) backhoe version only) Template Name: OM_1_col Template Date: 1994_04_29

Tool required - One 24 mm (15/16 inch) wrench for hexagonal head bolts STEP 1

STEP 3

Park the machine on the flat, level ground, stop the engine, engage parking brake and remove the starter switch key.

Install the new pad and the bolt.

STEP 4 Repeat step 2 and 3 for the other pads.

STEP 2

1 2 TRIM THIS EDGE

CK98N003

Remove the 3 bolt (1) and the pad (2).

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MAINTENANCE/ADJUSTMENTS

Service specification Torque tightening check ........................................................Every day for five day after replace a bucket tooth Fastening hardware ...................................................................230 Nm (170 lbf ft)

Tool required - One 24 mm (15/16 inch) wrench for hexagonal head bolts - A torque wrench

Installation

STEP 1

STEP 1

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Removal

CD96B028

Remove the fastening hardware.

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REPLACING A BACKHOE BUCKET OR LOADER BUCKET TOOTH

CD96B028

Install a new tooth and the appropriate shims adjustments.

STEP 2

CD96B028

Remove the tooth.

CD96B028

Install the fastening hardware.

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Template Name: OM_1_col Template Date: 1994_04_29

STEP 2

Template Name: OM_1_col Template Date: 1994_04_29

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Template Name: OM_1_col Template Date: 1994_04_29

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MAINTENANCE/ADJUSTMENTS

ENGINE TROUBLESHOOTING INCIDENT

Template Name: OM_1_col Template Date: 1994_04_29

Ignition on : Nothing happens in "start" position.

The engine turns over but does not start (no exhaust smoke).

POSSIBLE CAUSES

SOLUTIONS

Direction of travel control lever not in neutral

Put lever in neutral

Battery discharged

Recharge or replace battery

Bad contact at terminals, cables broken

Clean terminals or replace

Fuel tank empty

Fill fuel tank

Blocked fuel lines

Check and blow through lines

Dirty fuel filter

Replace fuel filter

Fuel lift pump inoperative

Consult your CASE Dealer

Fuel injection pump inoperative

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Engine difficult to start or will not start (smoke at exhaust).

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Engine starts but then stops.

Engine runs rough at low idle.

Engine cranking speed too low

Check battery, starter motor and cables

Contaminated fuel

Drain and clean the fuel circuit

Dirty air filter

Clean the air filter

Air in fuel

Bleed fuel circuit

Valves incorrectly adjusted

Adjust valve clearance

Fuel injection pump timing incorrect

Consult your CASE Dealer

Contaminated fuel

Drain and clean the fuel circuit

Air in fuel

Bleed fuel circuit

Idle speed too low

Consult your CASE Dealer

Air in fuel

Bleed fuel circuit

Level in fuel tank too low

Fill fuel tank

Dirty fuel lines or filter

Blow through lines, replace fuel filter

Idle speed too low Fuel injection pump inoperative

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Consult your CASE Dealer

INCIDENT

POSSIBLE CAUSES

SOLUTIONS

Air in fuel

Bleed fuel circuit

Idle speed too low Fuel injection pump timing incorrect Engine idle is rough when hot.

Injection orifices clogged or do not function Engine mountings broken

Consult your CASE Dealer

Defective high pressure lines Fuel injection pump inoperative Engine runs at too low a temperature.

Temperature sender inoperative Thermostat inoperative

Consult your CASE Dealer

Accelerator linkage out of adjustment Engine does not reach normal speed without load.

High speed adjustment screw out of adjustment

Consult your CASE Dealer

Engine misfires.

Contaminated fuel

Drain and clean the fuel circuit

Air in fuel

Bleed fuel circuit

Valves incorrectly adjusted

Adjust valve clearance

Leaks in fuel injection lines Valve springs broken

Consult your CASE Dealer

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High speed regulator out of adjustment

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MAINTENANCE/ADJUSTMENTS

Engine oil pressure too low.

Incorrect oil level

Fill to level, check for leaks

Oil is diluted, incorrect viscosity

Change the oil, check for source of condensation

Clogged oil filter

Change oil filter

Relief valve stuck in open position Faulty seal on inlet hose Worn oil pump, worn bearings

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Consult your CASE Dealer

Template Name: OM_1_col Template Date: 1994_04_29

Injector needle jammed

MAINTENANCE/ADJUSTMENTS INCIDENT

Template Name: OM_1_col Template Date: 1994_04_29

Engine temperature too high.

POSSIBLE CAUSES

SOLUTIONS

Engine coolant level too low

Add engine coolant, check for leaks

Slack alternator/fan belt

Check, replace belt tensioner

Radiator fins blocked

Blow through fins

Clogged hoses

Inspect, replace hoses

Radiator cap does not operate correctly

Change the cap

Thermostat inoperative Temperature sender inoperative Water pump inoperative

Consult your CASE Dealer

Excess fuel or incorrect fuel pump timing

Engine knocks.

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Incorrect fuel quality

Drain and refill with correct fuel

Air in fuel system

Bleed fuel circuit

Fuel injection pump timing incorrect

Consult your CASE Dealer

Injector nozzles inoperative

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Engine lacks power.

Incorrect fuel quality

Drain tank, blow through lines

Dirty air filter

Clean or change air filter

Air in fuel system

Bleed fuel circuit

Clogged fuel filter or fuel system

Change filter, blow through lines

Oil level too high

Lower to maximum mark on dipstick

Fuel return line clogged

Remove obstructions, replace tube

Air or exhaust gas leak at turbocharger (if equipped)

Correct the air or exhaust gas leak

Valves incorrectly adjusted Accelerator linkage out of adjustment Turbocharger does not function correctly (if equipped) Fuel injection pump timing incorrect Injection orifices do not function correctly Fuel injection pump inoperative

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Consult your CASE Dealer

SOLUTIONS

Air in fuel system

Bleed fuel circuit

Dirty air filter

Clean or change the elements

Air leaks at compressor

Correct the air leak

Operating temperature too low

Check thermostat and cooling system

Fuel injection pump timing incorrect Injector nozzles inoperative Turbocharger does not function correctly (if equipped)

Consult your CASE Dealer

Template Name: OM_1_col Template Date: 1994_04_29

Excess smoke when under load.

POSSIBLE CAUSES

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INCIDENT

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MAINTENANCE/ADJUSTMENTS

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ELECTRICAL SYSTEM

FUSES AND RELAYS Template Name: OM_1_col Template Date: 1994_04_29

CK98G019

CP99E001

Main fuse box is next to the battery and secondary fuse/relay board is located at the front of the side console. Remove the cover plate to gain access to the fuses and relays.

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IMPORTANT : Before replacing fuses, remove the battery master switch key (optional).

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

Fuses Power board fuses 20

10

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13 21

9 12

32

11

18

7

31

22 8

1

30

4

17

19 24

16 5

28

23

29

6

2 3

27 26

15 14

25

33 CS99E501

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Main fuse box 1 2 3 4 5

Alternator .........................................................................................125 amps Cab (Ignition) .....................................................................................80 amps Cab (Battery) .....................................................................................80 amps Ignition Feed (Thermostart) ...............................................................20 amps Starter Relay and Solenoid................................................................40 amps

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Headlight - Main - Left ......................................................................7.5 amps Headlight - Main - Right....................................................................7.5 amps Headlight - Dip - Left.........................................................................7.5 amps Headlight - Dip - Right ......................................................................7.5 amps Sidelights - Left/Number Plate .............................................................3 amps Sidelights - Right .................................................................................3 amps Indicators .............................................................................................5 amps Hazard ...............................................................................................10 amps Worklights - Front ..............................................................................15 amps Worklights - Front ..............................................................................15 amps Worklights - Rear ...............................................................................15 amps Worklights - Rear ...............................................................................15 amps Rotating Beacon ................................................................................15 amps Brake Light - Left .................................................................................3 amps Brake Light - Right...............................................................................3 amps Instrument Pack Illumination ...............................................................3 amps Difflock / 4WD ...................................................................................7.5 amps Clamp / Q/A Digger / Q/A Loader .....................................................7.5 amps RTD / Unloader Valve ..........................................................................5 amps Fr Wiper / Rear Wiper / Fr Wash / Rear Wash ..................................15 amps Interior Light / Radio .........................................................................7.5 amps Front Horn / Rear Horn ......................................................................10 amps Ride Control Solenoids......................................................................10 amps Gearbox - Forward/Reverse ................................................................5 amps Fuel Solenoid / Fuel Enrich ..............................................................7.5 amps HMU ..................................................................................................15 amps Air Conditioning Switch.....................................................................7.5 amps Cigar Lighter ......................................................................................15 amps Heater................................................................................................25 amps Switch Pack & I Pack - Ignition ..........................................................10 amps Switch Pack & I Pack - Battery ............................................................3 amps Battery Relay Coils ..............................................................................5 amps Ignition Relay Coils ..............................................................................5 amps

Template Name: OM_1_col Template Date: 1994_04_29

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

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ELECTRICAL SYSTEM

ELECTRICAL SYSTEM

Relays Template Name: OM_1_col Template Date: 1994_04_29

8 15

7

14

13 11 12 5

25 10

6

1

9

2

21

3

23 22

24

4

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20 26

19 18

17

16 27 CS99E501

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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Headlight - Main Headlight - Dip Sidelights / Number Plate / Illum Inst Pack Brake Lights Hazard enable Indicator/hazard enable Front Wiper Rear Wiper Front Washer Rear Washer Front Horn / Rear Horn Indicators flasher unit Front Worklights Rear Worklights Rotating Beacon Float enable relay Clamp

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Digger Quick Attach RTD Unloader Loader Quick Attach Ride Control Solenoids Gearbox - Forward Gearbox - Reverse 4WD Switch Hose Burst Gearbox - neutral

Template Name: OM_1_col Template Date: 1994_04_29

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18 19 20 21 22 23 24 25 26 27

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ELECTRICAL SYSTEM

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ELECTRICAL SYSTEM

BATTERY Template Name: OM_1_col Template Date: 1994_04_29

!

WARNING : Remove the battery master switch key (disconnected) before carrying out any servicing work on the Electrical System.

Access to the battery Tool required - Two13 mm (1/2 inch) wrench for hexagonal head bolts Remove the bolts and remove the cover plate.

NOTE : There batteries do not require the addition of distilled water.

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CP99E005

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!

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

!

WARNING : A spark or flame can cause the hydrogen in a battery to explode. To prevent any risk of explosion, observe the following instructions : - Remove the battery master switch key (disconnected).

- 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 objects.

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

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!

WARNING : Batteries produce explosive gases. Keep away any flame, spark or cigarettes. Always provide good ventilation when charging a battery or using a battery in an enclosed space. Always protect your eyes when working near a battery.

Replacing a battery Tool required - One 10 mm (3/8 inch) wrench for hexagonal head bolts - One 13 mm (1/2 inch) wrench for hexagonal head bolts STEP 3

1

CK98F042

2

CK98G020

Remove the battery master switch key (optional).

Remove the bolt (1), the clamping bar (2) and remove the old battery.

STEP 2

STEP 4

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STEP 1

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ELECTRICAL SYSTEM

Install the new battery.

1

2

CK98G020

Disconnect the cables (first from the negative terminal then the positive terminal).

CK98G020

Install the clamping bar (2) and the bolt (1).

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Template Name: OM_1_col Template Date: 1994_04_29

STEP 5

ELECTRICAL SYSTEM STEP 6

Template Name: OM_1_col Template Date: 1994_04_29

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

STEP 7 Connect the cables (first to the positive terminal, then the negative terminal).

!

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

STEP 8

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CK98F041

Install the battery master switch key (optional).

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

IMPORTANT : Make sure that the voltage of the booster batteries is the same as that of the machine circuit (12 volts).

Tools required - Two 13 mm (1/2 inch) wrench for hexagonal head bolts - Jumper cables

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

STEP 4 Start the engine.

STEP 5 First disconnect the negative (-) jumper cable, then disconnect the positive (+) jumper cable from the booster battery.

STEP 6 Install the cover plate and the bolts.

STEP 2 Connect the positive (+) jumper cable to the positive (+) terminal of the machine’s battery.

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Template Name: OM_1_col Template Date: 1994_04_29

CP99E005

Remove the bolts and remove the cover plate.

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STEP 3

STEP 1

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CONNECTING A BOOSTER BATTERY

ELECTRICAL SYSTEM

ALTERNATOR Service specification Template Name: OM_1_col Template Date: 1994_04_29

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

!

WARNING : Before carrying out any welding on the machine or repair work on the electrical circuit, disconnect the battery and disconnect the B+ and D+ wires on the alternator. When reconnecting, check the wire markings.

IMPORTANT : Do not use steam cleaning apparatus or cleaning solvent to clean the alternator.

Have the alternator checked by your CASE Dealer.

NOTE : Make sure the terminal protectors are correctly installed.

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CD98G026

STARTER MOTOR

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Service specification Inspection.................................................................................... Every 1000 hours Have the starter motor checked by your CASE Dealer.

NOTE : Make sure the terminal protectors are correctly installed.

CK98G021

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ELECTRICAL SYSTEM

CHECKING ELECTRICAL HARNESSES Steering harness ........................................................................... Every 500 hours Loader attachment harness .......................................................... Every 500 hours Make a visual inspection of the harnesses and potentiometers. Look for signs of wear and chafing and check the routing and fastening of the cables. In the event of problems, contact your CASE Dealer.

IMPORTANT : All service work on the electrical circuit should be carried out with the battery master switch key (optional) removed.

BULBS Operator’s compartment light ........................................................................... 5 W Instrument panel indicator lamp .................................................................... 1.2 W

Headlights .................................................................................................. 55/60 W Front side lights (on headlight) .......................................................................... 4 W Front direction indicators ................................................................................. 21 W Rear direction indicators ................................................................................. 21 W Brake lights/Rear side light .......................................................................... 21/5 W

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Instrument panel gauge ................................................................................ 1.2 W

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Service specifications

Front working lights ......................................................................................... 48 W Rear working lights.......................................................................................... 48 W

Licence plate light (specific to certain countries)............................................... 5 W

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Template Name: OM_1_col Template Date: 1994_04_29

Rotating beacons ............................................................................................ 55 W

ELECTRICAL SYSTEM

REPLACING A BULB IMPORTANT : Never touch a tungsten iodide bulb with your fingers.

Template Name: OM_1_col Template Date: 1994_04_29

Cab interior light

Instrument panel light

Tool required

Tool required

- One flat-headed screwdriver

- One cross-headed screwdriver

STEP 1

STEP 1

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CP99D003

CP99D008

Remove the lens.

Remove the four screws.

STEP 2

STEP 2

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CK98N002

Remove the clip, the bulb and install a bulb of the same wattage (5 W).

STEP 3

CD98G020

Remove the instrument panel and turn it over. Turn the bulb holder to the left and remove it.

Install the lens.

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ELECTRICAL SYSTEM

Install a bulb of the same wattage.

Indicator lamp : 1.2 W Gauge/indicator backlighting : 1.2 W STEP 4 Install the instrument panel and the four screws.

Headlights Tool required CP98G011

- One cross-headed screwdriver

Remove the bulb and install a bulb of the same wattage (55/60 W).

STEP 1

STEP 4

STEP 5 Install the light unit. Install the retaining frame and the four screws.

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Install the bulb holder in the light unit.

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STEP 3

STEP 3

CK99E026

Remove the four screws and remove the light unit.

CD98G025

To change a side light bulb, carry out Step 1 then remove the bulb and install a bulb of the same wattage (4 W). Install the retaining frame and the four screws.

CK98G023

Remove the bulb holder from the light unit.

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Template Name: OM_1_col Template Date: 1994_04_29

STEP 2

ELECTRICAL SYSTEM

Template Name: OM_1_col Template Date: 1994_04_29

Front direction indicator

Rear lights

Tool required

Tool required

- One cross-headed screwdriver

- One cross-headed screwdriver

STEP 1

STEP 1

CK99E026

CK98G024

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Remove the two screws and remove the lens.

Remove the two screws and remove the lens.

STEP 2

STEP 2

1

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2

CD98G024

Remove the bulb and install a bulb of the same wattage (21 W).

STEP 3 Install the lens and the two screws.

CD98G023

Remove the bulbs and install bulbs of the same wattage.

(1) Direction indicator (21 W).

(2) Brake light/Side light (21/5 W).

STEP 3 Install the lens and the two screws.

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ELECTRICAL SYSTEM

Front working lights

STEP 2

- One cross-headed screwdriver STEP 1

CD98G021

Remove the clip and the bulb holder.

Remove the bulb and install a bulb of the same wattage (48 W).

STEP 3 Install the bulb holder and the clip.

STEP 4 Install the light unit. Install the retaining frame and the two screws.

Rear working lights Tool required

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CK99E027

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Tool required

- One cross-headed screwdriver STEP 1

Remove the two screws, remove the retaining frame and remove the light unit.

CD98G018

Remove the two screws and remove the light unit.

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Template Name: OM_1_col Template Date: 1994_04_29

CD98G022

ELECTRICAL SYSTEM STEP 2

STEP 2

Template Name: OM_1_col Template Date: 1994_04_29

CD98G018

CD97E095

Remove the clip and the bulb holder.

Remove the bulb and install a bulb of the same wattage (48 W).

Raise the clip and remove the bulb.

STEP 3

Replace the bulb by a bulb of the same wattage (55 W).

Install the bulb holder and the clip.

STEP 3

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STEP 4

IMPORTANT : Never touch a tungsten iodide bulb with your fingers.

Install the light unit. Install the two screws.

STEP 4

Rotating beacon

Install the lens and its three retaining screws.

Tool required - One cross-headed screwdriver

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STEP 1

1

2

CD97E094

Remove the three screws (2) and remove the lens (1).

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ELECTRICAL SYSTEM

Licence plate light (specific to certain countries) - One cross-headed screwdriver STEP 1

CD98K021

CD98K006

Remove the screw and the lens.

VERTICAL ADJUSTMENT OF THE CAB-MOUNTED FRONT AND REAR WORKING LIGHTS Rear working lights Front working lights

CK99E028

Vertical adjustment manually.

is

carried

out

CK99E027

Vertical adjustment is carried out with the two screws.

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Remove the bulb and install a bulb of the same wattage (5 W).

Template Name: OM_1_col Template Date: 1994_04_29

Tool required

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STEP 2

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.

Place a tablespoonful of Shell Oil Company VPI crystals (or equivalent) 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 on the instrument panel.

9.

Clean or replace the air filter elements.

10. Coat the exposed portions of the cylinder rods and control valve spools with 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 building where the temperature is above 0°C. Make sure the battery is clean. Check the electrolyte level regularly and make sure it is correct.

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STORAGE

Starting up after storage Replace the fuel filter.

2.

Fill the engine cooling system with engine coolant.

3.

Check the condition of the alternator belt. Replace it if necessary.

4.

Fill the engine with oil and check the oil level.

5.

Check the hydraulic fluid level.

6.

Check the transmission oil level.

7.

Check the oil levels in the rear axle.

8.

Check the oil levels in the front drive axle and reduction gears (4 Wheel drive).

9.

Grease all the machine’s linkages.

11. Install the battery.

12. Fill the fuel tank.

13. Bleed air from the fuel supply system.

14. Check the condition and pressure of the tyres.

15. Start the engine.

!

WARNING : Check the machine for leaks and for broken, defective or missing parts.

!

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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10. Use a paraffin-based solvent to remove the anti-corrosion product from the hydraulic cylinder rods.

Template Name: OM_1_col Template Date: 1994_04_29

1.

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Do not start the engine before carrying out the following operations :

SPECIFICATIONS

ENGINE Template Name: OM_1_col Template Date: 1994_04_29

Make and type ........................................................................ PERKINS 1004-40T Displacement ........................................................................................... 3.99 litres Number of cylinders .............................................................................................. 4 Bore and stroke.................................................................................100 x 127 mm Injection system ............................................................................ FASTRAN direct Air filter ..................................................Dry type – two stage – restriction indicator Oil filter ............................................................... screw-on cartridge, total flow type Compression ratio ....................................................................................... 17.25:1 SAE J 1349 horsepower ........................................... 71.5 kW (96 hp) @ 2200 rpm ISO 9249 horsepower .................................................... 66.5 kW (hp) @ 2200 rpm ISO 9249 maximum torque .................................................... 371 Nm @ 1400 rpm

ELECTRICAL SYSTEM

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Voltage ........................................................................................................ 12 volts Battery (single) ........................................................................ 12 volts (115 amp/h) Battery (double) ........................................................................12 volts (72 amp/h) Alternator ...................................................................................Standard - 70 amp Air conditioning - 100 amp

CAB

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ROPS and FOPS type (with protection against rolling over and falling objects).

Tinted safety glass – wide glazed surface giving total visibility.

Operator’s seat with adjustable suspension. Class III as per 1980 ISO/DIS 7096.

Fresh air heater/blower unit, full heating control including demist on front and rear windows.

Optional air conditioning.

MACHINE WEIGHT Maximum authorised weight ........................................................ 8700 kg (3944lb)

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SPECIFICATIONS

TRANSMISSION Two phase, integrated with engine flywheel.

Stall ratio ................................................................................................... 2.87 to 1

Gearbox Make ........................................................................................................ TURNER Type : Direction of travel control with 4 synchronised gears.

4 forward and 4 reverse gears (Specific to certain countries, the fourth gear is not fitted).

Electrical transmission cut-out using push button on the gear change lever or on the loader attachment control lever.

Travel speed

First gear ................................................................................. 5.52 kph (3.43 mph) Second gear ............................................................................ 8.87 kph (5.51 mph) Third gear ............................................................................ 20.28 kph (12.60 mph) Fourth gear.......................................................................... 40.80 kph (25.35 mph)

Template Name: OM_1_col Template Date: 1994_04_29

NOTE : Specific to certain countries, the fourth gear is inoperable in forward and reverse.

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Engine Speed 2200 rpm Speeds in forward and reverse.

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Torque converter

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SPECIFICATIONS

AXLES Fixed rear axle Template Name: OM_1_col Template Date: 1994_04_29

Make ......................................................................................................CARRARO Spiral bevel crown wheel and pinion driving though axle-end epicyclic hubs.

Oscillating front axle Make ......................................................................................................CARRARO

TYRES Inflation pressure

Dimensions and type

Bar

lbf/in2

W15L x 24,16.9 x 24 12P R4 SG

2.2

32

W15Lx24,16.9 14,5P NOKIA

2.8

41

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W15Lx 24,16.9R x M27

2.2

32

W15L x 24,17.5LR x M27

1.8

26

WHEEL TIGHTENING TORQUE Front wheel nuts ........................................................................300 Nm (220 lbf ft) Rear wheel nuts .........................................................................300 Nm (220 lbf ft)

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BRAKES Service brakes Oil-immersed disc brakes mounted inboard, on the rear drive shafts. Hydraulic operation by brake pedal master cylinders, incorporating independent and compensating functions for site and highway use.

Parking or emergency brake Hand-lever and cables operated through a totally separate mechanical system to directly operate the service brakes.

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SPECIFICATIONS

Type ...................................................................................................... Hydrostatic Pressure .................................................................................175 bar (2540 lbf/in2)

Turning circle Turning circles are the same for both 4WD and 2WD machines Outside front wheels ........................................................................ 8.2 m (26’ 11”) Outside bucket ................................................................................. 10.9 m (35’ 9”)

HYDRAULIC SYSTEM Pump Two crankshaft driven gear pumps

Loader control valve Two spool closed centre mono block valve, incorporating circuit relief valves for head and rod sides of bucket and main lift cylinders. Single lever operation of bucket and lift spools.

An optional three spool closed centre valve is available. Where fitted, the additional spool can be used for attachments, such as clamshell bucket.

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Combined flow ............ 160 L/min (42.0 US Gal) at 2200 rpm and MRV at 225 bar First pump ..................... 80 L/min (21.0 US Gal) at 2200 rpm and MRV at 225 bar Second pump ................ 80 L/min (21.0 US Gal) at 2200 rpm and MRV at 225 bar

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STEERING

Template Name: OM_1_col Template Date: 1994_04_29

Maximum working pressure ............................................................. 225 – 0/+7 bar

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SPECIFICATIONS

Backhoe control valve Template Name: OM_1_col Template Date: 1994_04_29

The backhoe control valve comprising two closed centre mono block valves. A four spool valve controls the digging functions through two control levers. Circuit relief valves protect the boom, dipperstick, bucket and swing circuits.

The second mono block valve contains two lever operated stabiliser spools and can have an additional spool for auxiliary equipment such as a hammer.

Solenoid valves operate the sideshift clamp, (sideshift backhoe), craning valve (centremount backhoe) and optional digger bucket quick attach.

A separate foot pedal operated valve controls the optional extendable dipper.

Maximum working pressure .............................................................. 225 – 0/+7bar

Filtration On return circuit, by 13 micron interchangeable cartridge-type filter.

VIBRATION TRIM THIS EDGE

The machinery safety directive 93/392/EEC requires that machinery be vibration tested.

The CASE machines were all measured in hand vibration tests to be less than 2.5 m/s2.

For body vibrations, the CASE machines were all measured to be less than 0.5 m/s2.

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SPECIFICATIONS

CYLINDERS

Arm (quantity 2)...................................................................................685 x 90 mm Bucket (quantity 1) ............................................................................515 x 115 mm 7 in 1 (quantity 2) ................................................................................245 x 70 mm

Backhoe attachment Boom 4.5 m (quantity 1) ....................................................................994 x 120 mm Boom 4.9 m (quantity 1) ....................................................................974 x 120 mm Dipper (quantity 1).............................................................................943 x 100 mm Extendable dipper (quantity 1) ..........................................................1346 x 63 mm Swing (quantity 2) ...............................................................................225 x 90 mm Bucket (quantity 1) ..............................................................................724 x 90 mm Stabiliser – Sideshift (quantity 1 per stabiliser) ...................................643 x 45 mm Stabiliser – Centremount (quantity 1 per stabiliser) ............................646 x 90 mm

CAPACITIES Fuel tank ................................................................................ 120 ltr (33.0 US Gal) Hydraulic reservoir ................................................................... 45 ltr (12.4 US Gal) Engine (with filter) .................................................................. 10.7 ltr (3.0 US Gal) Front drive axle differential ........................................................... 8 ltr (2.2 US Gal) Reduction gear .......................................................................... 1.1 ltr (0.3 US Gal) Rear axle ................................................................................. 22.5 ltr (6.2 US Gal) Transmission .............................................................................. 15 ltr (4.1 US Gal) Cooling system........................................................................ 16.5 ltr (4.5 US Gal)

CYCLE TIMES Engine set to 2200 rpm, Hydraulic oil at 55 - 60° Raising (with self level) ........................................................................ 5.2 seconds Lowering (power down) ....................................................................... 4.2 seconds Lowering (float) .................................................................................... 2.6 seconds Dumping (at maximum height) .............................................................. 1.2 second

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Diameter x stroke

Template Name: OM_1_col Template Date: 1994_04_29

Diameter x stroke

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Loader attachment

SPECIFICATIONS

BUCKETS Loader Template Name: OM_1_col Template Date: 1994_04_29

SAE Capacity

2388 mm (94 inch)

1.0 m3 (1.3 yd3)

2286 mm (90 inch)

0.96 m3 (1.26 yd3)

2134 mm (84 inch)

0.89 m3 (1.18 yd3)

2286 mm (90 inch)

0.952 m3 (1.041 yd3)

2386 mm (96 inch)

0.997 m3 (1.09 yd3)

Width

SAE Capacity

High capacity

600 mm (24 inch)

0.213 m3 (0.233 yd3)

Standard Capacity

305 mm (12 inch)

0.076 m3 (0.083 yd3)

450 mm (18 inch)

0.113 m3 (0.124 yd3)

600 mm (24 inch)

0.168 m3 (0.184 yd3)

750 mm (30 inch)

0.227 m3 (0.248 yd3)

900 mm (36 inch)

0.286 m3 (0.312 yd3)

Standard

Multi-purpose

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Width

Backhoe

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N P R

C

F B

I H G

E A D

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Template Name: OM_1_col Template Date: 1994_04_29

O

Q

S

M LK J

CS99D521

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SPECIFICATIONS

GENERAL DIMENSIONS

SPECIFICATIONS Backhoe bucket 300 mm

600 mm

900 mm

Template Name: OM_1_col Template Date: 1994_04_29

A (Front wheel track).................. 1902 ........................ 1902........................... 1902 B (Front light vertical location) ..................... 1997 ........................ 1997........................... 1997 C (Front light horizontal location) .................. 372 ........................... 372............................. 372 D (Machine max. width) ............. 2386 ........................ 2386........................... 2386 E (Rear wheel track) .................. 1902 ........................ 1902........................... 1902 F (Machine max. height) ............ 3778 ........................ 3778........................... 3778 G (Rear indicator vertical location ....................... 893 ........................... 893............................. 893 H (Rear reflector vertical location) ...................... 829 ........................... 829............................. 829

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I (Brake/rear light location) .......... 772 ........................... 772............................. 772 J (Lowest implement height) ....... 250 ........................... 250............................. 250 K (Transport position height) ....... 300 ........................... 300............................. 300 L (Bucket tip height (MP)) ........... 869 ........................... 869............................. 869 M (Height to top of exhaust)....... 2799 ........................ 2799........................... 2799

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N (Front overhang (MP bucket))........................... 2122 ........................ 2122........................... 2122 * Standard bucket .................. 2154 ........................ 2154........................... 2154 O (Minimum machine height) ..................................... 375 ........................... 375............................. 375 P (Wheelbase) ........................... 2090 ........................ 2090........................... 2090 Q (Rear overhang) ..................... 1823 ........................ 1751........................... 1971 R (Overall machine length) ........ 6035 ........................ 5963........................... 6183 * Standard bucket .................. 6067 ........................ 5995........................... 6215 S (German bucket transport limit) ........................ 3465 ........................ 3465........................... 3465

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SPECIFICATIONS

Template Name: OM_1_col Template Date: 1994_04_29

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Operator’s de luxe adjustable suspension seat, with seat belt.

Front and rear working lights.

Road lights.

Horn.

Reversing audible warning device.

Complete instrument panel.

Audible warning device (failures in main functions).

Loader bucket return to dig.

Loader beam support strut.

Cold starting assistance.

Standard tyres.

Fender trim.

Rotating beacons.

Safety device for placing direction of travel control in neutral position.

Stabilizer cylinder safety valves.

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STANDARD ACCESSORIES

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ALPHABETICAL INDEX

Template Name: OM_1_col Template Date: 1994_04_29

A

C

Air conditioning ............................... 248 Air filter ............................................ 225 Air filter restriction warning lamp ....... 56 Air intake filter cab heater ............... 250 Alternator ........................................ 280 Alternator charge warning lamp ........ 56 Ashtray .............................................. 72 Axles ............................................... 292

Cycle times ..................................... 295 Cylinder leak inspection.................. 247 Cylinders......................................... 295

B

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Backhoe attachment auxiliary hydraulic tool controls ................. 116 Backhoe attachment auxiliary hydraulic tools............................. 147 Backhoe attachment boom unlocking lever.............................. 71 Backhoe attachment boom unlocking switch............................ 69 Backhoe attachment controls............ 81 Backhoe attachment operating instructions.................................. 174 Backhoe attachment sideshift ......... 137 Backhoe attachment sideshift carriage locking and unlocking switch ............................................ 70 Battery............................................. 276 Battery box ...................................... 110 Battery master switch...................... 110 Before operating the machine ......... 117 Brake check .................................... 254 Brake fluid ....................................... 239 Brake pedal ....................................... 64 Brakes ............................................. 292 Buckets ........................................... 296 Bulbs ............................................... 281 C Cab ................................................. 290 Cab doors ......................................... 52 Cab interior light ................................ 62 Capacities ....................................... 295 Checking electrical harnesses ........ 281 Cigar lighter....................................... 72 Connecting a booster battery .......... 279 Cooling system ............................... 205

D Decals............................................... 27 Differential lock ............................... 145 Differential locking pedal................... 64 Direction indicator lamp .................... 55 Direction indicator lever, horn and lighting switch ........................ 61 Direction of travel control lever ......... 59 Direction of travel lever indicator lamp ............................... 54 E Electrical system............................. 290 Electronic system............................ 127 Emergency cut-out button................. 58 Engine..................................... 201, 290 Engine accelerator pedal .................. 63 Engine alternator and fan belt......... 245 Engine bonnet................................. 112 Engine coolant ................................ 205 Engine coolant temperature gauge ........................................... 57 Engine coolant temperature warning lamp ................................ 56 Engine fault warning lamp ................ 54 Engine oil pressure warning lamp.............................................. 57 Engine tachometer............................ 57 Engine throttle lever.......................... 67 Engine troubleshooting ................... 268 Engine valve tip clearance adjustment.................................. 246 Environment.................................... 184 Extendable dipper........................... 261 F First aid kit and documentation pack storage compartment ........... 63 Fluid and lubricant capacities ......... 185 Fluids and lubricants....................... 182

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Front and rear axle and reduction gears ........................... 235 Front and rear windshield washer reservoir ......................... 107 Front drive axle engagement switch ............................................ 66 Front windshield washer control........ 68 Front windshield wiper control........... 67 Front working light switch .................. 65 Fuel injectors................................... 259 Fuel level gauge ................................ 57 Fuel system..................................... 210 Fuel tank ......................................... 108 Fuses and relays ............................. 272 Fuses and relays location ................. 71

Levels ............................................. 198 Lifting the machine.......................... 156 Load lifting ...................................... 148 Loader attachment and backhoe attachment controls ...................... 88 Loader attachment controls .............. 77 Loader attachment operating instructions ................................. 170 Loader attachment support strut............................................. 111 Loader bucket mounted forks ......... 150 Loader bucket return-to-dig adjustment .................................. 243 Loader or backhoe attachment selector button .............................. 99 Loader quick attach locking/unlocking switch ............... 70

G Gear change lever and transmission dump button............. 60 General dimensions ........................ 297 Grease points .................................. 186 H Hand signals ..................................... 46 Hazard warning switch ...................... 61 Heating, ventilation and air conditioning controls ..............102 Horn switch ....................................... 67 Hourmeter ................................. 55, 178 Hydraulic enable switch .................... 69 Hydraulic filter restriction warning lamp................................. 57 Hydraulic pumps flow control ............ 69 Hydraulic reservoir ..........................109 Hydraulic system ..................... 220, 293 I Identification of main components .................................. 12 Instructions for use ..........................162 Instrument panel ............................... 54 Intervals........................................... 179 J

M Machine inspection and cleaning ...................................... 246 Machine weight............................... 290 Main beam indicator lamp................. 54 Manual operation of the backhoe attachment ................... 161 Manual operation of the loader arms................................. 160 Manual operation of the steering control valve.................. 159 Maximum working loads ................. 149 O Official documents .............................. 7 Operating the machine ................... 118 Operating the machine in cold weather ............................... 133 Operating the machine in hot weather................................. 133 Operating the machine in water ...... 157 Operator’s compartment controls...... 58 Operator’s compartment windows...................................... 105 Operator’s seat ................................. 74

Job site travel .................................. 168 301

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L

Template Name: OM_1_col Template Date: 1994_04_29

F

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ALPHABETICAL INDEX

ALPHABETICAL INDEX

Template Name: OM_1_col Template Date: 1994_04_29

P

S

Parking brake indicator lamp ............ 54 Parking brake inspection and adjustment .................................. 252 Parking brake lever ........................... 64 Parking the machine ....................... 158 Plastic and resin parts..................... 185

Stabilizer controls ........................... 100 Standard accessories ..................... 299 Starter motor................................... 280 Starter switch .................................... 58 Starting the engine.......................... 122 Starting up in normal conditions ..... 125 Starting up safety devices............... 126 Steering .......................................... 293 Steering and axles .......................... 258 Steering column tilting lever.............. 62 Steering mode switch ....................... 73 Steps and access handles................ 53 Stopping the engine........................ 132 Storage areas ................................... 63 Storage compartment ....................... 62 Storing the machine........................ 288 Sunvisor............................................ 61

R

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Radiator and oil cooler .................... 244 Radio compartment........................... 71 Rear view mirrors ............................ 107 Rear windshield washer control ........ 68 Rear windshield wiper control ........... 68 Rear working light switch .................. 66 Releasing the pressure in the hydraulic system ................... 217 Removal and installation of quick attach loader bucket .......... 142 Replacing a backhoe bucket ........... 140 Replacing a backhoe bucket or loader bucket tooth ..................... 265 Replacing a bulb ............................. 282 Replacing a stabilizer pad ............... 264 Return to dig switch .......................... 70 Ride control system ........................ 113 Ride control system accumulator ................................ 255 Right, left, front, and rear of the machine .................................... 8 Road travel...................................... 163 ROPS/FOPS cab ............................ 256 Rotating beacons ............................ 114 Rotating beacons switch ................... 67 Running-in period............................ 120 S Safety instructions............................. 16 Servicing instructions ...................... 177 Setting the backhoe attachment in the road travel position............ 138 Setting the machine in the backhoe attachment working position ....................................... 134 Side light indicator lamp .................... 55 Speedometer .................................... 55

T To the owner....................................... 6 Tool box .......................................... 114 Tooling ............................................ 115 Towing the machine........................ 157 Transmission .................. 230, 259, 291 Transmission oil temperature warning lamp ................................ 57 Transporting the machine ............... 153 Troubleshooting test socket.............. 71 Turbo-charger ................................. 260 Type, serial number and year of manufacture of the machine ........... 9 Tyres............................................... 292 V Vertical adjustment of the cab-mounted front and rear working lights.............................. 287 Vibration.......................................... 294 W Wheel chock ................................... 115 Wheel tightening torque.................. 292 Wheels and tyres ............................ 241

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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.

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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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Printed in U.K.

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