Case 9007 Crawler Excavator Operator's Manual 6-6361 - PDF DOWNLOAD

OM 9X6 JAUNE Gabarit MM.qxd

31/10/2007

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9007 Crawler Excavator

Operator’s Manual Cre 6-6361 GB Replaces Cre 6-6360 GB

Operator’s Manual

Cre 6-6361 GB Replaces Cre 6-6360 GB

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Template Name: OM_1_col Template Date: 1994_04_29

9007 Crawler Excavator Alt= to hide template information Alt+ to display template information

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Template Name: OM_1_col Template Date: 1994_04_29

THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH. The Safety Decals on this machine use the words Danger, Warning or Caution, which are defined as follows: • DANGER: Indicates an immediate hazardous situation which, if not avoided, will result in death or serious injury. The color associated with Danger is RED. • WARNING: Indicates an potentially hazardous situation which if not avoided, will result in serious injury. The color associated with Warning is ORANGE. • CAUTION: Indicates an potentially hazardous situation which if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. The color associated with Caution is YELLOW. If safety Decals on this machine are ISO two panel Pictorials, decals are defined as follows:

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• • • •

The first panel indicates the nature of the hazard.

The second panel indicates the appropriate avoidance of the hazard.

Background color is YELLOW. Prohibition symbols such as if used, are RED.

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WARNING IMPROPER OPERATION OF THIS MACHINE CAN CAUSE INJURY OR DEATH. BEFORE USING THIS MACHINE, MAKE CERTAIN THAT EVERY OPERATOR: • Is instructed in safe and proper use of the machine.

• Reads and understands the Manual(s) pertaining to the machine.

• Reads and understands ALL Safety Decals on the machine.

• Clears the area of other persons.

• Learns and practises safe use of machine controls in a safe, clear area before operating this machine on a job site.

It is your responsibility to observe pertinent laws and regulations and follow CASE instructions on machine operation and maintenance.

Reproduction or translation, even partial, is prohibited without written aurthorization from CASE France Company Copyright  1999 CASE France

Cre 6-6361 GB Issued February 1999 (Revised October 1999)

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IDENTIFICATION NUMBER/MACHINE COMPONENTS ........................... 10 - 13 TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE ........................ 10 NOISE LEVELS ............................................................................................. 11 MACHINE COMPONENTS ............................................................................ 12

CONTROLS/INSTRUMENTS/ACCESSORIES ........................................... 34 - 75 CAB DOOR .................................................................................................... 34 STEPS AND ACCESS HANDLES ................................................................. 35 OPERATOR’S COMPARTMENT CONTROLS ............................................. 36 OPERATOR’S SEAT ..................................................................................... 57 WINDSHIELD ................................................................................................ 60 HEATING AND VENTILATION ...................................................................... 63 HEATING AND VENTILATION CONTROLS ................................................. 64 AIR CONDITIONING ..................................................................................... 66 FUEL TANK ................................................................................................... 68 REAR VIEW MIRROR ................................................................................... 68 RIGHT-HAND SIDE HOOD ........................................................................... 69 ENGINE HOOD ............................................................................................. 69 LOWER PANELS ........................................................................................... 70 WINDSHIELD WASHER RESERVOIR ......................................................... 70 LOAD HANDLING EYE ................................................................................. 71 SAFETY VALVE ............................................................................................ 71 OPTIONAL TOOL VALVES ........................................................................... 72 OPTIONAL TOOL SUPPLY VALVES ............................................................ 73 FUEL TANK FILLER PUMP ........................................................................... 74 OPERATING INSTRUCTIONS ................................................................. 76 - 113 BEFORE OPERATING THE MACHINE ........................................................ 76 MACHINE OPERATION ................................................................................ 77 RUN-IN PERIOD ............................................................................................ 79 STARTING THE ENGINE .............................................................................. 80 BRINGING THE MACHINE UP TO OPERATING TEMPERATURE ............. 83 ENGINE OPERATION ................................................................................... 84 OPERATING THE MACHINE IN COLD WEATHER ..................................... 85 OPERATING THE MACHINE IN HOT WEATHER ........................................ 85 STOPPING THE ENGINE ............................................................................. 86 MACHINE OPERATION ................................................................................ 87 1

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SAFETY/DECALS/HAND SIGNALS ........................................................... 14 - 33 SAFETY INSTRUCTIONS ........................................................................... 14 DECALS ......................................................................................................... 26 HAND SIGNALS ............................................................................................ 30

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TO THE OWNER ........................................................................................... 5 - 9 TO THE OWNER ............................................................................................. 6 RIGHT, LEFT, FRONT AND REAR OF THE MACHINE ................................. 8

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TABLE OF CONTENTS

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Template Name: OM_1_col Template Date: 1994_04_29

Operating Instructions (continued) MACHINE TRAVEL ....................................................................................... 89 TRANSPORTING THE MACHINE ................................................................ 92 HANDLING THE MACHINE .......................................................................... 94 LOAD HANDLING ......................................................................................... 95 LOAD HANDLING CHART ............................................................................ 96 OPERATING THE MACHINE IN WATER ..................................................... 97 OPERATING THE MACHINE ON SLOPING GROUND ............................... 98 OPERATING THE BACKHOE BUCKET ....................................................... 99 QUICK IMPLEMENT INSTALLATION AND REMOVAL .............................. 100 PARKING THE MACHINE ........................................................................... 103 TOWING THE MACHINE ............................................................................ 105 USING OPTIONAL TOOLS ......................................................................... 106 AUXILIARY HYDRAULIC CIRCUITS .......................................................... 108 HANDLING THE HYDRAULIC BREAKER .................................................. 110 BREAKING TECHNIQUES ON THE HYDRAULIC BREAKER ................... 110 CHOICE OF TOOLS ON A HYDRAULIC BREAKER .................................. 111 SPECIAL CONDITIONS OF USE ON A HYDRAULIC BREAKER ............... 112

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SERVICING INTERVALS ....................................................................... 114 SERVICING INSTRUCTIONS .....................................................................

HOURMETER ..............................................................................................

INTERVALS .................................................................................................

HYDRAULIC BREAKER INTERVALS .........................................................

118 114 115 116 118

LUBRICATION/FILTERS/FLUIDS ......................................................... 119 FLUIDS AND LUBRICANTS ........................................................................

ENVIRONMENT ..........................................................................................

FLUID AND LUBRICANT CAPACITIES AND SPECIFICATIONS ..............

GREASE POINTS .......................................................................................

GREASING THE HYDRAULIC BREAKER ..................................................

GREASING THE TURNTABLE TEETH ......................................................

GREASING THE SWING REDUCTION GEAR ...........................................

LEVELS .......................................................................................................

ENGINE .......................................................................................................

COOLING SYSTEM ....................................................................................

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

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

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

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

TRACK ROLLERS AND IDLER WHEELS ..................................................

TRAVEL REDUCTION GEARS ...................................................................

163 119 122 123 124 134 135 135 136 138 141 144 146 148 157 161 162

MAINTENANCE/ADJUSTMENTS .......................................................... 164 TRACKS ......................................................................................................

RADIATOR AND OIL COOLER ...................................................................

FAN AND ALTERNATOR DRIVE BELT ......................................................

FUEL TANK FILTER ....................................................................................

191 164 171 172 174

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ELECTRICAL SYSTEM .......................................................................... 192 FUSES .........................................................................................................

BATTERIES .................................................................................................

CONNECTING BOOSTER BATTERIES .....................................................

ALTERNATOR .............................................................................................

STARTER MOTOR ......................................................................................

197 192 194 196 196 197

STORAGE .............................................................................................. 198 - 199 STORING THE MACHINE ........................................................................... 198 SPECIFICATIONS .................................................................................. 200 ENGINE .......................................................................................................

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

UNDERCARRIAGE .....................................................................................

SAFETY DEVICES ......................................................................................

INDICATORS AND GAUGES ......................................................................

WARNING AND INDICATOR LAMPS .........................................................

NOISE LEVELS ...........................................................................................

WEIGHTS ....................................................................................................

BOOMS ........................................................................................................

DIPPER ........................................................................................................

DOZER BLADE ............................................................................................

BACKHOE BUCKETS .................................................................................

DITCH-CLEANING BUCKETS ....................................................................

V-LINE BUCKET ..........................................................................................

MACHINE OVERALL DIMENSIONS ...........................................................

WORKING RANGE ......................................................................................

MAXIMUM LOADS ......................................................................................

HYDRAULIC BREAKER SPECIFICATIONS ...............................................

213 200 200 201 201 201 201 202 202 202 202 202 203 203 203 204 207 210 212

ALPHABETICAL INDEX .......................................................................... 214 - 216 3

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174 174 175 175 176 178 179 180 182 184 186 187 188 188 189

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Maintenance/Adjustments (continued) ADJUSTING ENGINE ROCKER ARM CLEARANCE .................................

INSPECTING AND CLEANING THE MACHINE .........................................

CHECKING FOR CYLINDER LEAKAGE ....................................................

PLASTIC AND RESIN PARTS ....................................................................

REPLACING A TOOTH TIP ON A BACKHOE BUCKET .............................

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

WELDING ON THE MACHINE ....................................................................

REPLACING A TOOL ON A HYDRAULIC BREAKER ................................

REPLACING A TOOL BUSHING ON A HYDRAULIC BREAKER ...............

REPLACING A HYDRAULIQUE HAMMER .................................................

WEAR LIMITS ON A HYDRAULIC BREAKER ............................................

INSPECTING AND SERVICING THE QUICK COUPLER ..........................

FIRE EXTINGUISHER (not supplied) ..........................................................

AIR CONDITIONING ...................................................................................

ENGINE TROUBLESHOOTING ..................................................................

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Template Name: OM_1_col Template Date: 1994_04_29

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TO THE OWNER

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Dealer’s Stamp

Case France Rue des Meuniers 60330 Le Plessis-Belleville FRANCE 5

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

CP99A003

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9007 HYDRAULIC CRAWLER EXCAVATOR

TO THE OWNER

TO THE OWNER Template Name: OM_1_col Template Date: 1994_04_29 TRIM THIS EDGE

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This manual contains important information about the safe operation, adjustment and maintenance of your CASE machine. Refer to the Detail Index at the end of this manual for locating specific items about your machine. This machine conforms to current safety regulations.

Use this manual as a guide. Your machine will remain a reliable working tool as long as it is kept in good working condition and serviced properly.

Do not operate or permit anyone to operate or service this machine until you or the other persons have read and understand the safety, operation and maintenance instructions in this manual. Use only trained operators who have demonstrated the ability to operate and service this machine correctly and safely.

This machine, with standard equipment and authorized attachments, is intended to be used for below ground level digging and general earthmoving purpose such as trenching, truck loading, material rehandling and ditch cleaning. If the machine is to be used for lifting objects, make sure that the machine is properly equipped and follow the instructions and safety precautions in this manual.

Do not use this machine for any application or purpose other than those described in this manual. Consult an authorized CASE Dealer or the CASE Corporation on changes, additions or modifications that can be required for this machine to comply with various country regulations and safety requirements. Unauthorized modifications can cause serious injury or death. Anyone making such unauthorized modifications is responsible for the consequences.

This Operator’s Manual is to be stored in the manual compartment provided on this machine. Make sure this manual is complete and in good condition. Contact your CASE Dealer to obtain additional manuals. Contact your CASE Dealer for any further information or assistance about your machine. Your CASE Dealer has CASE Corporation approved service parts. You CASE Dealer has technicians with special training that know the best methods of repair and maintenance for your machine.

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A certificate defining the weight shown on the manufacturer’s plate - Indication that the weight shown on the manufacturer’s plate is a value using the heaviest configuration and that it does not always correspond to the transport configuration.

1 - The following directives: - EEC 86/662 as modified : Noise level - EEC 89/336 : Electromagnetic compatibility 2 - The following European standards : - EN 474-1 : Safety - General requirements - EN 474-5 : Safety - Hydraulic excavators including load lifting IMPORTANT : An original of this “CE” certificate is supplied with each machine and must be kept carefully by the owner.

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A “CE” certificate of conformity - For a new construction equipment machine, series produced to a type approved design, designed and manufactured in accordance with the requirements of European directive 98/37, concerning machine safety and mainly:

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Official documents

Template Name: OM_1_col Template Date: 1994_04_29

IMPORTANT : The official documents supplied with the machine must be kept by the owner so as to be able to present them to any inspecting authority which may request them.

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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” are used in this manual to indicate the sides as they are seen from the operator’s seat when the cab is over the idler wheels.

The illustration below shows the machine in normal TRAVEL position. In normal TRAVEL position, the cab is over the idler wheels. The travel reduction gears are at the rear of the upperstructure.

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2 CS98M544

1 FRONT 2 REAR 3 RIGHT-HAND SIDE

4 LEFT-HAND SIDE 5 TRAVEL REDUCTION GEARS 6 IDLER WHEELS

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IDENTIFICATION NUMBER/MACHINE COMPONENTS

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

When ordering parts, obtaining information or assistance, always supply your CASE Dealer with the type and serial number of your machine or accessories.

Write the following in the spaces below: The type, serial number and year of manufacture of your machine, accessories and the serial numbers of the various hydraulic and mechanical components.

Machine

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2 CS99A668

CP98N006

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

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

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(3) Year of build ....................................

Engine Make and type ........................................................................................................

Serial number..........................................................................................................

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

Swing reduction gear ..............................................................................................

Travel reduction gears ............................................................................................

Travel control valve .................................................................................................

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

Swing control valve .................................................................................................

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IDENTIFICATION NUMBER/MACHINE COMPONENTS

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5

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8 CS97A032

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3 CS99C624

(1) Serial number ...................................................................................................

(2) Weight................................................................................................................

(3) Operating pressure ............................................................................................

(4) Type ...................................................................................................................

(5) Part number .......................................................................................................

(6) Date of manufacturer .........................................................................................

(7) Safe working load ..............................................................................................

(8) Operating flow....................................................................................................

NOISE LEVELS External

Internal

CS99A854

CS98N516

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 (modified).

This decal shows the value in decibels of the interval noise level in the operator’s compartment, as guaranteed by the manufacturer. As per european directive 86/ 662/EEC (modified).

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Template Name: OM_1_col Template Date: 1994_04_29

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Hydraulic breaker (optional) Alt= to hide template information Alt+ to display template information

Quick coupler (optional)

IDENTIFICATION NUMBER/MACHINE COMPONENTS

MACHINE COMPONENTS

7 1

5 12

18

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CP98M005

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10 20 13

15 14 3 17 2 19

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Template Name: OM_1_col Template Date: 1994_04_29

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The 9007 is an all hydraulic machine. It consists of an undercarriage fitted with tracks and a turntable bearing which supports the upperstructure frame. The upperstructure frame supports the attachment, at the front end of the machine, plus the engine, hydraulics and cab. When the operator works the controls, the engine-driven variable flow pump delivers hydraulic fluid under pressure to the control valves. The control valves distribute the hydraulic fluid to the various cylinders and hydraulic motors employed. A cooling system and oil cooler keep the fluid temperature down to normal working temperature.

Key to main components Cab/Operator’s compartment Upperstructure Undercarriage Steps Access handles Boom Boom cylinders Dipper Dipper cylinder Backhoe bucket Backhoe bucket cylinder Engine compartment Counterweight Upper rollers Lower rollers Travel reduction gears Idler wheels Tracks Dozer blade Hydraulic reservoir and fuel tank

Template Name: OM_1_col Template Date: 1994_04_29

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

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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 depend 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 stability, braking and steering characteristics of the machine. If you are in any doubt, consult your CASE Dealer.

The safety messages in this manual 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 being done (earthmoving, handling, drilling, etc.), the safety measures for private or public work-sites are those which conform to current regulations in the country concerned, or the type of operation concerned (mining, quarrying, tunnelling).

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The safety instructions given in this manual are a summary of the basic rules to be respected at all times and do not exempt you from insurance requirements or from abiding by the highway code.

Always keep this manual in the storage compartment provided for it. Make sure it is always complete and in good condition.

If you wish to obtain extra copies, or copies in languages other than that of the country of use, consult your CASE Dealer.

BP97H098

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SAFETY/DECALS/HAND SIGNALS

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Different types of job will require different types of protective equipment.

Items such as hard hats, safety shoes, heavy gloves, reflector type jackets, respirators, ear protection and eye protection may be required. Before starting a job, determine what protective equipment will be necessary. Use this equipment at all times.

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Do not attempt to operate this machine unless you have first read and perfectly understood the safety messages and instructions featuring in this manual.

Operating the machine requires full attention and care on the part of the operator can avoid accidents. Get to know the machine’s possibilities and limitations and the working space required. There are areas of poor visibility in the working range of the machine. Have someone guide you for all areas where visibility is not perfect.

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Grease, oil, mud or (in winter) ice on the steps and access handles can cause accidents. Make sure they are kept clean at all times.

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Every day, inspect the machine to detect any signs of oil or hydraulic fluid leakage. Tighten the connections or replace any defective components as necessary.

•

Make sure the windshield wiper works correctly.

Make sure you are perfectly familiar with hand signals in daily use on the worksite so as to be able to obtain help with tight maneuvers or when carrying out operations where visibility is poor.

Before undertaking any travel or working operations during hours of darkness, make sure the lighting and signalling equipment is fully operative.

Before undertaking any travel, make sure the door and all lower panels and hoods are properly locked or fastened.

Check that no tools or other items have been left on the machine (be it on the undercarriage or the upperstructure) or in the operator’s compartment.

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visibility. Keep the windshield, rear view mirror and windows clean at all times.

The operator must be alone on the machine at all times. Do not allow anyone to stand on or around the machine.

When alighting from or getting into the operator’s compartment, it is mandatory for the upperstructure to be in line with the undercarriage.

When alighting from or getting into the operator’s compartment, always face the machine and use the steps and access handles.

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Avoid loose uncovered long hair, jewellery or any other items which could get caught up in machinery.

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BEFORE USING THE MACHINE fitting clothing, loose or • Remove any obstructions which hinder

SAFETY/DECALS/HAND SIGNALS

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Be sure you know the position and function of each control. Using controls wrongly can cause serious injury.

Check all controls and safety devices in a safe, open area before starting work.

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Keep away from dangerous areas such as ditches, overhangs, unstable ground, etc... Inspect the worksite before starting work and look for any danger areas.

•

Before moving the machine to work in a new area, walk around to determine all possible causes of accidents there.

Holes, obstacles, piles of rubble and other potential sources of danger on the worksite can cause serious injury.

•

Be ready to meet emergencies.

Always carry a first aid kit and if possible, fire extinguisher (not supplied) within easy reach on board. Make sure the fire extinguisher is regularly serviced in conformance with the manufacturer’s instructions.

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Make sure you understand the symbols used on the machine safety decals. Keep the decals clean so that they are perfectly legible at all times.

Work out a means of convenient escape from the machine (emergency exit via the windshield or on the rear window glass) in the event of the cab door being jammed or the machine turning over.

Make sure you are perfectly familiar with traffic regulations and special safety equipment requirements before transporting this machine on a public highway.

When loading trucks, never swing the load over the truck cab.

Before undertaking any travel on the job site, make sure the itinerary to be followed is completely safe. If bridges are to be crossed, make sure they are perfectly capable of supporting the weight of the machine.

Always steer round large obstacles such as boulders, big trees, etc...

If the machine is equipped with a quick coupler (optional), it is mandatory for the switch to be in the locked position when operating the machine.

If the machine is equipped with quick coupler (optional), it is mandatory to ensure that the safety shaft and locking pin are correctly installed in the quick coupler.

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SAFETY/DECALS/HAND SIGNALS

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Avoid running the engine in a confined space. If there is no alternative, proper ventilation must be provided at all times.

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Do not allow anyone else on the machine. The passenger could fall or cause an accident.

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Never operate the working or travel controls unless you are properly seated in the operator’s seat.

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Before starting the engine, check the direction of travel (in forward drive, the reduction gears should be to the rear of the machine).

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Do not work near overhead high-voltage electric lines without checking before hand that all necessary measures have been taken to respect the minimum distances : Under 57 000 volts : 3 metres.

Over 57 000 volts : 5 metres.

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Study the position of any existing pipelines or conduits before starting work.

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

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Do not allow anyone to stand in the machine working area. Accidental operation of the upperstructure swing control or of an attachment control could cause an accident. Stop all operations until everyone has moved away.

Operate all controls gradually to ensure smooth machine operation.

Whenever load handling operations are to be carried out, it is imperative to adhere strictly to the instructions given in this manual and local legislation.

Never use the equipment for sweeping the ground to level out rubble or push objects (transversal stress on the attachment).

Stop the engine and remove the starter switch key when the machine is not in use, even for short periods of time.

Never climb down from the operator’s compartment leaving the engine running and without engaging the “Control locking switch ” on the left-hand control lever. Never forget this basic requirement.

It is imperative to raise the control cancellation lever whenever entering the operator’s compartment. Never forget this basic requirement.

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allowance for working conditions (sloping or rough ground), the road surface and weather conditions when driving the machine.

Template Name: OM_1_col Template Date: 1994_04_29

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When working on use standard traffic signs and take into consideration the working range of the upperstructure and its attachments.

Local regulations stipulate the number, type and location of reflector strips.

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MACHINE OPERATION a public highway, • Always make

SAFETY/DECALS/HAND SIGNALS

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When alighting from or getting into the operator’s compartment, it is mandatory for the upperstructure to be in line with the undercarriage.

Dust, smoke or mist can reduce visibility and cause an accident. Reduce speed or come to a complete halt until visibility has improved.

Never jump down from the machine.

When alighting from the machine or the upperstructure, always face the machine and use the steps and access handles.

In the event of an operating problem or failure, move the machine to a safe place, immediately lower the attachment to the ground, with the dipper cylinder rod and bucket cylinder rod completely extended or retracted, stop the engine and remove the starter switch key. Locate the problem, report it if necessary and take the necessary steps to warn others not to attempt to operate the machine.

If the machine is equipped with a quick coupler (optional), never tilt the switch to the unlocked position when operating the machine at work.

If the machine is equipped with a quick coupler (optional), never put your hands inside the quick coupler or attempt to adjust or repair it when the engine is running.

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SAFETY/DECALS/HAND SIGNALS

area is the space necessary for the machine to operate at the maximum range of the tool and at full swing (360°) plus 2 metres.

1

1. Working area.

2. Safety area.

2 CS97M019

PARKING THE MACHINE When parking the machine, proceed as follows :

6. Lock the cab door.

7. Make sure that all doors, hoods and lower panels are correctly locked.

1. Position the machine on flat, level ground, away from soft ground, excavations or poorly shored cavities.

8. Check that no part of the machine is encroaching on the highway. If this cannot be avoided, install the necessary regulation signalling equipment.

2. Place the upperstructure in line with the undercarriage, retract the attachment and dig the bucket into the ground.

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SAFETY AREA • The safety

3. Lower the dozer blade until it is resting on the ground.

Template Name: OM_1_col Template Date: 1994_04_29

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

5. Be absolutely sure to raise the control cancellation arm before leaving the operator’s compartment.

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SAFETY/DECALS/HAND SIGNALS

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BEFORE USING THE HYDRAULIC BREAKER (optional) • Do not attempt to operate this hydrau- • Every day, inspect

the hydraulic breaker to detect any signs of oil or hydraulic fluid leakage. Tighten the connections or replace any defective components and grease as necessary.

lic breaker unless you have first read and perfectly understood the safety messages and instructions featuring in this manual.

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Operating the hydraulic breaker requires full attention and care on the part of the operator can avoid accidents. Get to know the hydraulic breaker’s possibilities and limitations and the working space required.

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Make sure the hydraulic breaker is in good condition. Never use a hydraulic breaker which is in poor condition or if there are components missing, as this could cause serious injury.

Make sure the maintenance procedures explained in this manual are carried out correctly.

USING THE HYDRAULIC BREAKER (optional) yourself and the vicinity from • Do not operate the hydraulic hammer if

Protect flying chips of rock.

the tool is in contact with some part of the machine.

Wear ear protection when working with the machine door or windows open.

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Move everybody away before operating the hydraulic breaker.

Never immerse the hydraulic breaker in water as this could cause damage.

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Never use the hydraulic breaker to sweep the ground to spread rubble, to push objects or carry out lifting operations.

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Place the tool against the object at a 90 degree angle. Avoid small irregularities on the object which will break easily and cause either idle strokes or an incorrect working angle.

When demolishing vertical structures (e.g brick walls), place the tool against the wall at a 90 degree angle.

Use a safety screen to protect yourself from flying debris. Keep the cab windows closed during operation.

Do not operate the hydraulic breaker with the attachment cylinders up to the end of their stroke (extended or retracted).

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•

•

•

Do not strike in one spot for more than 15 seconds at a time. If the object does not break, or if the tool does not penetrate, stop the breaker and change the position of the tool.

•

For the hydraulic breaker to be most effective when breaking boulders work progressively in small steps from the outer edge towards the middle.

•

When breaking hard or frozen ground, use the benching method. Start by clearing a small area working from the edge. Then continue by breaking material towards the open area.

Do not operate the hydraulic breaker in the air, with nothing to hit. Frequent idle strokes have a deteriorating effect on the hydraulic breaker.

When breaking concrete, hard or frozen ground, never strike and pry with the tool at the same time. The tool may snap off. Bending may be caused by stones inside hard or frozen ground.

Be careful and stop striking if you encounter sudden resistance under the tool.

Keep the tool at a 90 degree angle at all times. If the object moves or if its surface breaks, correct the angle immediately. Keep the hydraulic hydraulic force and tool aligned.

The tool shank should be kept well greased during operation. Regular visual checks should be made during operation.

Template Name: OM_1_col Template Date: 1994_04_29

•

•

Listen to the noise the hydraulic breaker makes while you are using it. If the pitch of the noise rises and, at the same time, the force of impact diminishes, this means that the tool is not properly aligned with the material and/ or that there is not enough downward force on the tool. Realign the tool and press it firmly against the material.

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SAFETY/DECALS/HAND SIGNALS

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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 try to service this machine • Any unauthorized modifications made

Do not unless you have first read and perfectly understood the safety messages and instructions featuring in this manual.

to this machine can cause serious injury. Do not undertake any modifications without first consulting your CASE Dealer. Any modifications made must be in conformity with the technical specifications of the machine and any current safety legislation requirements.

When carrying out service work always wear suitable dress. Avoid loose-fitting clothing.

•

Before commencing any work on the machine, place a “Do not operate” tag on the right-hand control arm.

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

•

Badly carried out maintenance or adjustments can cause serious injuries. If you do not understand a servicing or adjustment procedure, contact your CASE Dealer.

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If the attachment is raised or if the machine moves without an operator, serious injury can result. Before carrying out maintenance on this machine, proceed as follows :

•

1. Park the machine on flat, level ground.

Certain components of the machine are subject to type approval. When replacing such components, it is mandatory to make sure that they conform to regulations. For safety’s sake, use genuine CASE parts.

Pressurized hydraulic fluid or grease which penetrates the skin can cause serious injury. Take the necessary safety precautions (safety clothing and protection for face and hands) to avoid such risks. Also, before using these products, read the manufacturer’s instructions concerning their use. If hydraulic fluid penetrates the skin, call a doctor immediately.

The pressure in the track tension cylinders is high. Follow the procedure described in this manual carefully for increasing or reducing track tension.

2. Lower the attachment and dozer blade until they are resting on the ground.

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

4. Block the tracks to prevent any machine movement.

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SAFETY/DECALS/HAND SIGNALS

•

•

The hydraulic breaker incorporates two accumulators. These accumulators remain constantly under pressure, event when the hydraulic breaker is removed from the machine. Do not try to service the accumulators. All service work on the accumulators must be carried out by your CASE Dealer.

Before carrying out any service work on the hydraulic breaker, make sure all pressure has been correctly released, in order to avoid any uncontrolled movement. See “Releasing pressure in the hydraulic system” in the “Lubrication/Filters/Fluids” Section.

Clean the machine regularly. Accumulations of grease, dirt and debris can cause injuries or damage the machine.

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•

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

Hydraulic breaker (optional)

Template Name: OM_1_col Template Date: 1994_04_29

•

Whenever carrying out a welding operation on the undercarriage or upperstructure carriage as authorized by the manufacturer and in accordance with his instructions, disconnect the batteries, disconnect the alternator B+ and D+ terminal wires and connect the welding apparatus earth cable to the component on which the welding operation is to be performed. Never connect the welding apparatus to the undercarriage when welding on the upperstructure (or vice-versa). Never connect the welding apparatus earth to a component of the hydraulic system.

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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 • Sparks can fly from the electrical sysa fire.

- Never refuel when the engine is running.

- Never smoke while refuelling.

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

• •

tem or the engine exhaust. Before running the machine in an area where there may be inflammable gasses, make sure there is adequate ventilation.

•

Always use a non-inflammable solvent for cleaning parts.

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A spark or naked light can cause the hydrogen in the batteries to explode.

To avoid all risk of explosion, be sure to follow the instructions below : - When disconnecting batteries cables, always disconnect the negative cable (-) first.

- When connecting batteries cables, always connect the negative cable (-) last.

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

- Do not weld, grind or smoke near the batteries.

• •

If possible, make sure there is a fire extinguisher (not supplied) within easy reach on board the machine. Make sure the fire extinguisher is regularly serviced in conformity with the manufacturer’s instructions.

Clean the machine regularly, removing all debris and inflammable material.

Make sure there are no leaks and replace any damaged hoses, lines or connectors. After any repair work, clean the machine before operating.

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When battery electrolyte freezes it can explode if your try to charge it or start up the engine with booster batteries.

To prevent the electrolyte from freezing, keep batteries charged at all times.

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coolant reservoir cap is removed while the system is still hot. Before removing the cap, let the system cool down and then turn the cap to its first notch, waiting until all pressure is released. Then remove the cap.

Template Name: OM_1_col Template Date: 1994_04_29

•

The electrolyte in cause serious burns. Batteries contain sulphuric acid. Avoid contact with skin, eyes and clothing.

Antidote : EXTERNAL : Rinse with water.

INTERNAL : Drink large amounts 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 immediately.

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•

PREVENTION OF BURNS the batteries can • Boiling coolant fluid can escape if the

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DECALS Template Name: OM_1_col Template Date: 1994_04_29

!

!

WARNING : An illegible or missing decal can have far-reaching consequences. Inspect decals daily.

WARNING : Make sure that the decals are perfectly legible, clean them regularly and replace decals that are destroyed, lost, painted over or no longer legible, with new ones. When parts bearing decals are replaced, be sure to put new decals on each new part.

When you clean the decals, use only a cloth, water and soap. Do not use solvents, gasoline, etc.

This chapter only covers decals relating to safety and machine operation and servicing. For information on all decals on the machine, consult the spare parts catalogue.

New decals can be obtained from your CASE Dealer. The part numbers are shown at the bottom of each decal.

TRIM THIS EDGE CS95M062

PDH0029

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This decal reminds the operator not to allow anyone to stand within the working range of the upperstructure frame while the engine is running.

This decal draws attention to the fact that, in certain positions, there can be interference between the attachment tool and the operator’s compartment. Always observe a minimum safety distance between the tool and the operator’s compartment (in case of swinging or accidental movements).

CS95M063

This decal reminds the operator not to allow anyone to stand within the working range of the attachment while the engine is running.

CS96D164

This decal shows that it is essential to read the operator’s manual before operating the machine.

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CS98N559

CS96D165

This decal shows the function of the lefthand and right-hand control levers. See “Left-hand control lever” and “Right-hand control lever” in the “Controls/Instruments/ Accessories” Section.

This decal shows the location of the fuel tank.

CS98N561

This decal shows the function of the travel control levers and pedals. See “Travel control levers and pedals” in the “Controls/Instruments/Accessories” Section.

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CS96D166

This decal shows the location of the hydraulic reservoir.

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SAFETY/DECALS/HAND SIGNALS

CS98B169

This decal warns that it is essential to stop the engine before opening the hood.

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Template Name: OM_1_col Template Date: 1994_04_29

PDE0768

This decal shows where to attach slings when handling the excavator. Use these points and these points only. See “Handling the machine” in the “Operating Instructions” Section.

SAFETY/DECALS/HAND SIGNALS

Template Name: OM_1_col Template Date: 1994_04_29

PDE0769

CS96C038

This decal shows where not to attach slings. Never try to use these points to handle the machine.

This decal warns that the fan and the fan belt must never be touched while the engine is running. Stop the engine before performing any operation.

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CS96C040

This decal warns that the exhaust system must never be touched while the engine is running or immediately after the engine has stopped.

CS96C179

This decal warns that the radiator must never be touched and that the radiator cap must never be removed while the cooling system is still hot. See “Cooling system” in the “Lubrication/Filters/Fluids” Section.

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CS96D163

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

CS98N560

This decal shows the location of the emergency hammer.

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CP99C002

CP99C003

These decal warn that there is a risk of flying pieces of rock, etc. and that special protective equipment must be installed before operation.

Template Name: OM_1_col Template Date: 1994_04_29

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These decals show the location of the accumulators and remind you that, whatever the service work, the accumulators will be under pressure. See your CASE Dealer.

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Hydraulic breaker (optional)

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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

Shut down the engine

PDE0002A

PDE0002

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Come to me

Move away from me

Wave hands back and forth (palms inwards).

Wave hands back and forth (palms outwards).

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PDE0003A

PDE0003

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SAFETY/DECALS/HAND SIGNALS

All stop and hold

PDE0004A

PDE0004

Emergency stop

Wave hands back and forth.

Wave hands back and forth.

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Stop

PDE0005A

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Go this far

PDE0005

Lower load or tool

PDE0006A

PDE0006

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Template Name: OM_1_col Template Date: 1994_04_29

Raise load or tool

SAFETY/DECALS/HAND SIGNALS

Slowly raise the load or tool

Slowly lower the load or tool

Template Name: OM_1_col Template Date: 1994_04_29

PDE0007A

PDE0007

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Turn the machine to the left (swing load left)

Turn machine right (swing load right)

To stop movement, stop moving hand and clench fist.

To stop movement, stop moving hand and clench fist.

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PDE0008A

PDE0008

Raise tool

Lower tool

PDE0009A

PDE0009

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Lower boom

PDE0010A

PDE0010

Extend dipper

PDE0011A

PDE0011

Empty tool

PDE0012A

PDE0012

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Template Name: OM_1_col Template Date: 1994_04_29

Fill tool

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Retract dipper

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Raise boom

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CAB DOOR Template Name: OM_1_col Template Date: 1994_04_29

3 1

A23949

A23946

The door can be latched in completely open position. To unlatch the door, tilt the lever (3) downwards.

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!

WARNING : Be careful not to get your hand or anything caught in the door when closing it.

!

WARNING : Do not leave the door ajar. Fix it in a latched position.

2

CD98N009

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To open the door, use the handle (1) from the outside and use the handle (2) from the inside.

NOTE : Use the starter switch key to lock the door.

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!

WARNING : Never jump down from the machine. When alighting from the machine or the upperstructure, always face the machine and use the steps and access handles.

!

WARNING : To get in or out of the cab, never use the left-hand control lever, the left-hand control cancellation arm or the door handle.

!

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

2 CK98M007

2

2 CK98M008

Template Name: OM_1_col Template Date: 1994_04_29

To get in or out of the machine use the steps (2) and access handles (1).

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!

WARNING : To get in or out of the cab, it is imperative that the upperstructure frame is in line with the undercarriage.

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STEPS AND ACCESS HANDLES

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CONTROLS/INSTRUMENTS/ACCESSORIES

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

WARNING : Before starting the engine, make sure that you are fully aware of the location of and the function of each control. Incorrect operation of the controls can cause serious injuries.

!

Location of controls and associated components 15

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13 12 11

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9

10 5

8 7

4

3

2

6 CS98M534

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1.

Operator’s seat

2.

Cab door unlatching lever

3.

Left-hand control arm

4.

Control cancellation lever

5.

Left-hand control lever, dipper and upperstructure swing controls

6.

Travel speed selection pedal

7.

Left-hand travel control pedal and lever

8.

Right-hand travel control pedal and lever

9.

Dozer blade lever

10. Option pedal 11. Instrument console 12. Right-hand control lever, boom and bucket controls TRIM THIS EDGE

13. Right-hand control arm 14. Cab interior lighting

Template Name: OM_1_col Template Date: 1994_04_29

15. Roof hatch

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CONTROLS/INSTRUMENTS/ACCESSORIES

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CONTROLS/INSTRUMENTS/ACCESSORIES

Right-hand control arm Template Name: OM_1_col Template Date: 1994_04_29

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1

4

3 5

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2

CS98M624

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CONTROLS/INSTRUMENTS/ACCESSORIES

NOTE : The starter switch key is also used to lock the cab door, the engine hood and the right-hand side panel.

2. ENGINE THROTTLE BUTTON - This button allows engine speed to be increased or lowered. For “low idle” position, turn the button to the left. For “Maximum speed”, turn the button to the right.

NOTE : If there is no change in engine speed, press and release the engine automatic idle speed selector (see item 8).

3. AUDIBLE WARNING DEVICE CUT-OUT BUTTON - Press this button to turn off the audible warning device.

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

5. WINDSHIELD WIPER SWITCH - This switch has three positions : “Off”, “Intermittent” and “Continuous”. Press the switch momentarily for intermittent operation, the first lamp comes on. Press the switch and hold it down longer to obtain continuous operation, the other lamp comes on. Press the switch once more for the function to cease.

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4. WINDSHIELD WASHER SWITCH - Press and hold down the switch to operate the windshield wiper and windshield washer. Release the switch for the function to cease.

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1. STARTER SWITCH - This switch has four positions, “ON” (contact), “START” (engine ignition), “OFF” (engine shut-down) and “HEAT” (engine pre-heating). See “Starting the engine” in the “Operating Instructions” Section.

Template Name: OM_1_col Template Date: 1994_04_29

IMPORTANT : Do not operate the windshield wiper if the windshield is dry, as this may damage the windshield wiper.

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Right-hand control arm (continued) Template Name: OM_1_col Template Date: 1994_04_29

8

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7

9

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6

CS98M624

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6. WORKING MODE SELECTOR - This allows one of two working modes to be selected. “Standard” mode (S) for ordinary duties and “Light” mode (L) for precision work. In “Light” (L) mode, all machine movements are slower. Press (L) to select “Light” mode - the corresponding (L) lamp comes on. Press (S) to select “Standard” mode - the corresponding (S) lamps comes on.

NOTE : When starting the engine, “Standard” (S) mode is automatically selected.

7. WORKING LIGHT SWITCH - This switch controls the attachment working light, the upperstructure frame working light and the cab working light. Press the switch once; the indicator lamp (1) in the control comes on and the upperstructure working light and the cab working light will light up. When the switch is pressed again, the indicator lamps (1) and (2) in the control come on and the upperstructure working light, the cab working light and the attachment working light will light up. Press the switch once more to extinguish all the working lights.

RADIO (optional) COMPARTMENT.

Template Name: OM_1_col Template Date: 1994_04_29

9.

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8. ENGINE IDLE SPEED SELECTOR - This button enables engine idle speed to be selected without having recourse to the engine throttle button. Press the button and the engine will automatically go into “Idle speed”. Press the button again and the engine will immediately revert to its original speed.

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CONTROLS/INSTRUMENTS/ACCESSORIES

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Left-hand control arm Template Name: OM_1_col Template Date: 1994_04_29

1

4

2

3

CS99K542

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5

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6

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2.

VENTILATION CONTROL - See “Heating and ventilation”.

3.

AIR CONDITIONING CONTROL (optional) - See “Air conditioning”.

4. CONTROL LOCKING SWITCH - This switch allows the machine controls to be locked. When this switch is pressed, the control levers and pedals will be inoperational, the attachment, travel and swing functions will not work and the “Control locking” indicator lamp lights up on the console. When the switch is pressed again, all functions become operational once more and the indicator lamp goes out. See item 9 under “Instrument console”.

WARNING : Before leaving the operator’s compartment, place the switch in locking position. Never forget this basic safety requirement.

5. UPPERSTRUCTURE SWING LOCKING SWITCH - This switch is used to lock the swing function. When the switch is pressed, the upperstructure swing function will be locked if the left-hand control lever is operated and the “Upperstructure swing lock” lamp on the instrument console comes on. Press the switch once more to unlock the swing function. The swing function becomes operational and the lamp on the console goes out. See item 8 under “Instrument console”.

6. EMERGENCY SHUT-DOWN SWITCH - This switch enables the engine to be shut down in case of any emergency or if it is not possible to stop the engine using the starter switch key. When the switch is pressed, the engine will stop and the switch lighting will come on. To start the engine again, press the switch. The switch light goes out and the engine may be started using the starter switch key.

IMPORTANT : This switch should only be used in case of an emergency. Do not use it on a day-to-day basis.

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!

Template Name: OM_1_col Template Date: 1994_04_29

1. HOURMETER -The hourmeter displays the total time that the engine has been operated, in hours and tenths of an hour. It also enables service operations to be scheduled (see “Servicing Intervals” Section). When the engine is running, the hourmeter functions and the green indicator lamp flashes.

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CONTROLS/INSTRUMENTS/ACCESSORIES

CONTROLS/INSTRUMENTS/ACCESSORIES

Left-hand control arm (continued) Template Name: OM_1_col Template Date: 1994_04_29

7

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8

11

10

CS99K542

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9

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IMPORTANT : Always sound the horn before operating the machine.

8. OPTIONAL TOOL AND OFFSET BACKHOE ENABLE SWITCH (if fitted) - This switch has two positions and is used to enable optional tools, such as a hydraulic breaker, etc. or the offset backhoe. In “ON” position, the optional tool is enabled, but the offset backhoe is not. In “OFF” position, the offset backhoe is enabled, but the optional tool is not. The switch works in conjunction with the option offset backhoe control pedal . See “Offset backhoe or option control pedal”.

9. QUICK COUPLER LOCKING/UNLOCKING CONTROL SWITCH (optional) See “Quick coupler locking/unlocking control switch”. Also see “Quick tool installation and release” in the “Operating Instructions” Section.

11. OVERLOAD INDICATOR SWITCH - This is a two-position switch which to be used when lifting loads. Place the switch in “ON” position. If the load to be lifted exceeds the authorized limit, the audible alarm will sound. In “OFF” position the switch is non-operational. See “Load handling” in the “Operating Instructions” Section.

Template Name: OM_1_col Template Date: 1994_04_29

IMPORTANT : Before undertaking any load handling operations, place the switch is “ON” position.

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10. ROTARY LIGHT SWITCH - This is a two-position switch which is used to operate the rotary light . In “ON” position, the rotary light comes on. In “OFF” position, the rotary light goes out.

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7. HORN SWITCH - Press the extremity of the left-hand control lever to operate the horn.

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Instrument console Template Name: OM_1_col Template Date: 1994_04_29

8

6

7

4

5

3

2

1 CS98M625

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WARNING : The console is a device to indicate the machine’s condition and to alert the operator quickly of any abnormalities by means of lamps indicators or buzzers. It is not to be used for determining the time for maintenance operations. The console can be damaged by water. Take care that it doesn’t get wet during rainy weather or when washing the machine.

NOTE : Wipe the monitor panel with a soft, dry cloth. Do not use solvents.

1. ENGINE COOLANT SOLUTION TEMPERATURE INDICATOR - The needle indicates the temperature of the engine coolant solution (C : Cold; H : Hot). The indicator operates when the starter switch key is in the “ON” position.

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IMPORTANT : If the needle reaches the area close to “H” move the machine to a safe place, lower the attachment to the ground, stop the engine, remove the starter switch key and check the cooling system to find the cause of the problem.

2. FUEL LEVEL INDICATOR - When the needle on the fuel gauge reaches the “E” area, fuel must be added to the fuel tank.

IMPORTANT : Do not wait until the fuel tank is completely empty before refilling or it will be necessary to bleed the fuel circuit.

3. ENGINE OIL PRESSURE WARNING LAMP - This warning lamp comes on and the audible warning device sounds if engine oil pressure is too low. If the warning lamp comes on during operation, move the machine to a safe area, lower the attachment to the ground, shut down the engine, remove the starter switch key and find the cause of the problem (engine oil level too low, restricted oil filter).

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4. ENGINE COOLANT/HYDRAULIC FLUID TEMPERATURE WARNING LAMP This warning lamp comes on and the audible warning device sounds if the engine coolant temperature or the hydraulic fluid temperature becomes too high. If the warning lamp comes on during operation, shut down the engine, remove the starter switch key and find the cause of the problem (check the radiator and the hydraulic fluid level).

5. BATTERY CHARGE WARNING LAMP - This warning lamp comes on and the audible warning device sounds if the alternator/fan belt is broken or if the alternator is no longer charging the batteries. If the warning lamp comes on during operation, move the machine to a safe area, lower the attachment to the ground, shut down the engine, remove the starter switch key and find the cause of the problem.

6. BATTERY ELECTROLYTE LEVEL WARNING LAMP - This warning lamp comes on and the audible warning device sounds if the battery electrolyte level is too low. If the warning lamp comes on during operation, move the machine to a safe area, lower the attachment to the ground, shut down the engine, remove the starter switch key and check the electrolyte level. See “Batteries” in the “Electrical System” Section.

IMPORTANT : Do not wait until the fuel tank is completely empty before refilling or it will be necessary to bleed the fuel circuit.

Template Name: OM_1_col Template Date: 1994_04_29

8. UPPERSTRUCTURE SWING LOCKING INDICATOR LAMP - This lamp comes on when the “Upperstructure swing locking switch” is pressed. See item 5 under “Lefthand control arm”.

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7. FUEL LEVEL WARNING LAMP - This warning lamp comes on and the audible warning device sounds if the level in the fuel tank is too low. Refill as soon as possible.

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CONTROLS/INSTRUMENTS/ACCESSORIES

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CONTROLS/INSTRUMENTS/ACCESSORIES

Instrument console (continued) Template Name: OM_1_col Template Date: 1994_04_29

10

11

9 CS98M625

9. CONTROL LOCKING INDICATOR LAMP - This indicator lamp comes on when the control locking switch is pressed, see “Left-hand control arm” (item 4). It also comes on when the control cancellation lever is raised. See “Control cancellation lever”.

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10. HIGH SPEED TRAVEL INDICATOR LAMP - This indicator lamp comes on when the travel speed selection pedal is used to obtain high speed. See “Travel speed selection pedal”.

11. PRE-HEATING INDICATOR LAMP - This indicator lamp comes on and the audible warning device sounds when the starter switch key is held in “HEAT” (engine preheating) position. See “Starting the engine” in the “Operating Instructions” Section.

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CK98M009

CK98M010

When the lever is lowered, attachment, travel and swing functions become operative once more.

Template Name: OM_1_col Template Date: 1994_04_29

!

WARNING : When climbing into or leaving the operator’s compartment, it is mandatory for the control cancellation lever to be in raised position. Never forget this basic safety requirement.

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The control cancellation lever has been designed to prevent the operator leaving the operator’s compartment without first placing the lever in raised position.

The control cancellation lever makes the control lever functions inoperative.

When the lever is raised, attachment, travel and swing functions are cancelled and the “Control locking indicator lamp” on the console comes on, see “Instrument console” (item 9).

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Control cancellation lever

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CONTROLS/INSTRUMENTS/ACCESSORIES

Template Name: OM_1_col Template Date: 1994_04_29

Dipper and upperstructure swing lefthand control lever

Boom and bucket righthand control lever 5

1 6 2

8

4 7 CS98M564

3

The speed of movement of the boom or the bucket depends on the control lever tilt angle. In the intermediate position both movements can be obtained simultaneously.

CS98M565

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The speed of movement of the dipper or the upperstructure swing depends on the control lever tilt angle. In the intermediate position both movements can be obtained simultaneously.

7 4

2 5

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8 1

CS98M554

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CS98M554

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The dipper extends.

The upperstructure turns to the left.

The dipper retracts.

The upperstructure turns to the right.

The boom lowers.

The bucket retracts.

The boom raises.

The bucket extends.

NOTE : The movements of the machine are shown on the “Control functions” decals.

See “Decals”.

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10

11

12

NOTE : Travel speed either forwards or in reverse depends on the position of the speed selector pedal. See “Travel speed selector pedal”.

NOTE : The movements of the machine are shown in the “Control functions” decals. See “Decals”.

CK98M012

Travel is controlled using the levers or pedals. To travel in a straight line, push the two levers (or press the two pedals) simultaneously to the front or to the rear.

To change direction, push one lever (or press one pedal) only. To turn on the spot, push one lever (or press one pedal) to the front and the other to the rear. See “Machine travel” in the “Operating Instructions” Section.

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11

10

12

CS98M544

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11.

12.

The left-hand track moves forwards.

The left-hand moves to the rear.

The right-hand track moves forwards.

The right-hand track moves to the rear.

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IMPORTANT : In the normal travel position, the operator’s compartment is above the idler wheels and the travel reduction gears are to the rear of the upperstructure. If the upperstructure is turned 180° in relation to the undercarriage, the lever functions are reversed.

Template Name: OM_1_col Template Date: 1994_04_29

Travel control levers and pedals

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CONTROLS/INSTRUMENTS/ACCESSORIES

CONTROLS/INSTRUMENTS/ACCESSORIES

Offset backhoe (if fitted) or option control pedal

Travel speed selector pedal

Template Name: OM_1_col Template Date: 1994_04_29

1

2 CK98M012

CK98M012

This pedal is to be used for operating either the offset backhoe or optional tools, such as the hydraulic breaker, etc...

This pedal allows one of two possible travel speeds to be selected.

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Slow speed, for slow travel or when maximum power is required (0 to 3.7 kph).

The precise function of the pedal will be determined by the control on the left-hand control arm; see “Optional tool and offset backhoe enable switch ”.

High speed, for travel on flat or gently undulating ground (0 to 5 kph).

Depending on equipment:

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1. The hydraulic breaker functions or the offset backhoe attachment offsets to the right.

2.

The offset backhoe offsets to the left.

IMPORTANT : Ask your CASE Dealer for advice on optional tools.

To select high speed, press the pedal down once and then release it. To select low speed, press the pedal down once again and then release it.

NOTE : When high speed is selected, an indicator lamp lights up on the instrument console. See “Instrument console” (item 10).

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Quick coupler locking/ unlocking control (optional)

2

1 1

CK98M012

2

Located to the right of the seat, this lever controls the movement of the dozer blade.

CK99G001

Located on the left-hand control arm, this control is used to lock and unlock the quick coupler. See “Quick implement installation and removal” in the “Operating instructions” Section.

Pull the lever towards you to raise the dozer blade.

Push the lever away from you to lower the dozer blade.

2.

The movement of the dozer blade stops when the lever is released. The lever returns to the neutral position.

NOTE : It is possible to lower the dozer blade from its raised position to the position resting on the ground when the engine is not functioning, by means of the control lever.

!

WARNING : Make sure that no one is in the operating area of the dozer blade before moving it.

To unlock, push the locking pin upwards and simultaneously press top of the switch (1). In this position audible warning device sounds and tool can be removed.

(3) the the the

NOTE : To remove the tool, it is necessary to push the locking pin (3) upward while pressing the switch (1) upward, since, for safety reasons, the switch alone cannot be pushed upwards.

To lock, press the bottom of the switch (2).

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1.

3

Template Name: OM_1_col Template Date: 1994_04_29

Dozer blade control lever

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CONTROLS/INSTRUMENTS/ACCESSORIES

CONTROLS/INSTRUMENTS/ACCESSORIES

Cab light

Cigarette lighter

Template Name: OM_1_col Template Date: 1994_04_29

A23883

CK98M035

The light is located on the right-hand cab upright and is controlled by a switch set in the lamp base.

The cigarette lighter is in the rear compartment.

IMPORTANT : Do not keep the cigarette lighter pushed in, to avoid damage.

Coat hanger hook TRIM THIS EDGE

Ashtray

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A23883

This hook is on the right-hand cab upright.

A23882

The ashtray is on the right-hand side of the cab. To empty the ashtray, press down on top and tilt.

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CONTROLS/INSTRUMENTS/ACCESSORIES

A23887

CP98N011

this hammer, located on the cab left-hand aupright, is for breaking the rear cab glass in case of an emergency.

IMPORTANT : Since roof hatch closing is assisted by two gas struts, simply follow through the closing movement without pulling or trying to hold it back.

Storage tray TRIM THIS EDGE

To open the roof hatch, release the lock and push the hatch upwards. To close the roof hatch, pull the lock downwards.

Cab door sliding window

CP98N012

CP98M004

When the locks are released, the window can be opened and closed to the left/right as required.

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Emergency hammer

Template Name: OM_1_col Template Date: 1994_04_29

Roof hatch

CONTROLS/INSTRUMENTS/ACCESSORIES

Sun shield Template Name: OM_1_col Template Date: 1994_04_29

CK99J001

The sun shield is fixed to the windshield and can easily be positioned as required.

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CONTROLS/INSTRUMENTS/ACCESSORIES

7 5

4 1 8 2

CD99A014

Suspension adjustment

Fore/aft adjustment

2

1

CD98N014

CD98N014

Suspension can be adjusted for any weight between 50 kg and 120 kg. Turn the control (1) in the + or - direction.

Hold the control (2) in raised position, slide the seat to the required position and then release the control.

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3

6

Template Name: OM_1_col Template Date: 1994_04_29

In order to operate the machine correctly and with maximum efficiency and comfort, adjust the seat to suit the weight and size of the operator.

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OPERATOR’S SEAT

CONTROLS/INSTRUMENTS/ACCESSORIES

Seat position adjustment Template Name: OM_1_col Template Date: 1994_04_29

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WARNING : Before tilting the seat back it is essential for the armrests to be in raised position to prevent them from fowling the control levers.

Armrest angle adjustment 3

CD98N014

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To raise or lower the front of the seat, hold the lever (3) in raised position. Move with the seat to desired position and then release the lever.

To raise or lower the rear of the seat, hold the lever (3) in lowered position. Move with the seat to the desired position and then release the lever.

5

CD98N017

Raise the front part of the armrest and adjust to the desired angle using the knob (5), then lower the armrest.

Seat back angle adjustment

Lumbar support adjustment

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6 4

CD99A015

To adjust the seat back angle, hold the lever (4) in raised position. Move with the seat back to the desired position and then release the lever.

CD99A015

Use the inflation bulb (6) to inflate the lumbar support. Press the button on the tip of the inflation bulb (6) to deflate the lumbar support.

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CONTROLS/INSTRUMENTS/ACCESSORIES

Seat belt

8 7

CD98N017

Sit comfortably in the seat, pull out a long section of belt and engage it in the fastening system (8).

NOTE : To make the headrest return to its initial position (to the rear), tilt it completely forwards and then release it.

NOTE : If the section of belt pulled out is not long enough, release it, so it rolls up and then pull it out again.

To release the seat belt, press down on the releasing lever (8).

IMPORTANT : Inspect the seat belt.

Make sure that it is not damaged, that the mounting screws are correctly tightened and replace any defective parts.

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CD98N016

The headrest (7) can be adjusted upwards and downwards and backwards and forwards.

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Headrest adjustment

Template Name: OM_1_col Template Date: 1994_04_29

The seat belt must be kept clean. Use only soap and water to clean the belt, do not use bleach or dies.

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CONTROLS/INSTRUMENTS/ACCESSORIES

WINDSHIELD Template Name: OM_1_col Template Date: 1994_04_29

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WARNING : Make sure you follow the instructions below properly. If the windshield is not handled correctly it could slip and injure your fingers or hand.

Opening STEP 3

STEP 1

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CD99J003

A23888

Fold the sun shield up against the windshield and disconnect the wiper electrical connector.

Pull both lock levers down.

STEP 4

STEP 2

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A23889

Hold the lower and upper handles and carefully raise the windshield. Push to the rear until the rear latch engages. Make sure that the windshield is correctly latched and can not move forward.

A23886

Release the left-hand lock and tilt it downwards.

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CONTROLS/INSTRUMENTS/ACCESSORIES

A23891

A23892

Engage the left-hand lock into the side of the cab.

Release the rear lock.

STEP 3

Closing TRIM THIS EDGE

STEP 1

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STEP 2

STEP 5

A23889

Hold both handles and carefully lower the windshield. Make sure the window is completely down.

A23891

Template Name: OM_1_col Template Date: 1994_04_29

Release the left-hand lock as shown above.

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CONTROLS/INSTRUMENTS/ACCESSORIES

Lower front window

STEP 4

Template Name: OM_1_col Template Date: 1994_04_29

When the windshield is opened, the lower window can be removed.

STEP 1

A23888

Make sure the top of the windshield is correctly latched.

STEP 5 A23875

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Pull the left and right lower window lock pins inwards and remove the lower window.

STEP 2

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A23885

Close the left-hand lock.

STEP 6

CK98N018

Place the lower window behind the operator’s seat and latch it with the left and right lock pins.

CD99J003

Reconnect the wiper electrical connector.

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CONTROLS/INSTRUMENTS/ACCESSORIES

HEATING AND VENTILATION Heater valve

CP99A004

The air vents can be used to direct the flow of air.

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Windshield defroster

IMPORTANT : In summer, turn off the heating by screwing down the heater valve into closed position.

CS99J511

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Template Name: OM_1_col Template Date: 1994_04_29

CK98M013

To obtain warm air, it is first necessary to unscrew the heater valve on the engine, so it is in open position.

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Air vents

CONTROLS/INSTRUMENTS/ACCESSORIES

HEATING AND VENTILATION CONTROLS These controls are located on the left-hand control arm.

Template Name: OM_1_col Template Date: 1994_04_29

1

2

3 TRIM THIS EDGE

4 CP99J001

Ventilation control

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1

To increase the flow, press button (A) until the required position is obtained. The corresponding indicator lamp will come on.

To reduce flow, press button (B) until the required position is obtained.

B

NOTE : For machines fitted with air conditioning (optional) see “Air conditioning”.

A CP98M003

This control can be used to increase or reduce the flow of air.

Position (I) : low flow.

Position (II) : medium flow.

Position (III) : high flow.

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Temperature control 2

To select any of these choices, press buttons (A) or (B) until the required position is obtained. The corresponding indicator lamp will come on.

B

Air recycling control 4

A CP99J002

This control is for increasing or reducing the temperature (red : warm, blue : cold).

To increase the temperature, press button (A) until the required position is obtained.

The corresponding indicator lights will come on. To reduce the temperature, press button (B) until the required position is obtained.

A

D

Template Name: OM_1_col Template Date: 1994_04_29

C

To select one of these two possible choices, use the control (H) to select the required position. The corresponding indicator lamp comes on.

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This control makes it possible to select one of two different kinds of air circulation.

(A) Air circulation within the cab itself.

(B) Air recycling.

B

E

C CP99J004

Air flow directional control 3

B

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CONTROLS/INSTRUMENTS/ACCESSORIES

A CP99J003

This control makes it possible to have air blowing from : (C) The upper vent only.

(D) The lower vent only.

(E) The upper and lower vents at the same time.

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CONTROLS/INSTRUMENTS/ACCESSORIES

AIR CONDITIONING (optional) Cooling mode

Template Name: OM_1_col Template Date: 1994_04_29

The air conditioning control is located on the left-hand control arm.

NOTE : To ensure correct functioning and full effectiveness of the air conditioning system, it must be run at least once a week, even if only for a short time.

STEP 1 If the temperature in the cab is extremely high, open the door and the windows to evacuate the hot air.

STEP 2 Start the engine. As soon as it reaches operating temperature, increase the engine speed.

CP98M002

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Air conditioning control button

STEP 3

This button is used for turning the air conditioning on and off.

On : press the button and the indicator lamp comes on.

Off : press the button and the indicator lamp goes out.

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NOTE : If the heater is functioning and the humidity level is high, turn the air conditioner on to reduce the humidity level.

CP98M002

Turn on the air conditioning and select the required temperature (blue indicator lamps).

STEP 4 Close the cab door and all at the windows.

STEP 5 Set the air conditioning in order to obtain an inside temperature of 10 degrees less than the outside.

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CONTROLS/INSTRUMENTS/ACCESSORIES

CP98M002

CP98M002

If the humidity level is high, start the air conditioning and adjust the heating once more.

Heating mode STEP 1

NOTE : When servicing the air conditioning system, see “Air conditioning” in the “Maintenance/Adjustments” Section.

Start the engine.

Template Name: OM_1_col Template Date: 1994_04_29

STEP 2

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Recycle the air from time to time.

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STEP 4

STEP 6

CP98M002

As soon as the engine reaches working temperature, select the required temperature (red indicator lamps). Set the ventilation control to medium flow (II) position.

STEP 3 Reduce the heating as the temperature rises.

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CONTROLS/INSTRUMENTS/ACCESSORIES

FUEL TANK Template Name: OM_1_col Template Date: 1994_04_29

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

1

When installing the fuel cap (1), make sure that it is correctly placed in the notches and then lock it by turning it up against the stop.

2

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WARNING : Never refill the fuel tank when the engine is running.

Never smoke during refuelling.

CK98M029

The fuel tank capacity is 140 litres.

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NOTE : Clean around the fuel cap before refuelling and do not remove the filter located in the filler orifice. See “Fuel tank filter” in the “Maintenance/Adjustments” Section.

NOTE : The fuel tank is fitted with a sight gauge (2).

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

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REAR VIEW MIRROR Before undertaking any travel, make sure the rear view mirror is clean and properly adjusted.

CP99A005

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CONTROLS/INSTRUMENTS/ACCESSORIES

The right-hand side hood must be opened to gain access to certain components on the machine. Use the starter switch key to unlock the hood.

Use the handle to tilt the side hood upwards.

!

WARNING : Before undertaking any travel, make sure that the hood is correctly locked.

CP98M008

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ENGINE HOOD

CK98M028

Use the starter switch key to open the hood.

The hood is fitted with a strut. To close the hood, swing it down and slam it to lock it.

IMPORTANT : Make sure that the strut is replaced in its retaining clip.

!

WARNING : Before undertaking any travel, make sure that the hood is correctly locked.

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Template Name: OM_1_col Template Date: 1994_04_29

CK98M027

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RIGHT-HAND SIDE HOOD

CONTROLS/INSTRUMENTS/ACCESSORIES

LOWER PANELS Template Name: OM_1_col Template Date: 1994_04_29

These panels are located under the upperstructure frame and give to certain machine components.

IMPORTANT : Do not operate the machine with the panels removed.

CP99A006

!

WARNING : Before undertaking any travel, make sure the panels are correctly locked.

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WINDSHIELD WASHER RESERVOIR IMPORTANT : Never operate the windshield washer control when the reservoir is empty. This could cause damage to the electric pump.

Remove the cap to fill the reservoir.

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

CK98M020

This reservoir, located on the left in the engine compartment, is equipped with an electric pump which is operated from the right-hand control arm. See item 4 under “Right-hand control arm”.

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CONTROLS/INSTRUMENTS/ACCESSORIES

!

WARNING : Never use the connecting rod eye if the bucket has been removed.

CK99J002

To handle a load, it is imperative for all slings and chains be attached to the connecting rod eye. See “Load Handling” in the “Operating Instructions” Section.

IMPORTANT : Never use the ring in the quick coupler (optional), if the machine is fitted with a quick coupler. The only load fixing point is the connecting rod eye.

IMPORTANT : This attachment point will only carry the load indicated in the maximum lift capacities table. See “Maximum lift capacities tables” in the “Operating Instructions” Section and “Maximum loads” in the “Specifications” Section.

SAFETY VALVE (optional)

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!

WARNING : Never weld hooks or lugs on the bottom plate of the bucket for handling operations. The only attachment point which may be used is the connecting rod eye.

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LOAD HANDLING EYE

Template Name: OM_1_col Template Date: 1994_04_29

The role of the safety valve is to stop the attachment from dropping due to valve spool leakage in neutral position or in the event of a line or hose accidentally breaking. In the latter event, they also ensure that the attachment may be lowered gently to the ground.

See “Load handling” in the “Operating Instructions” Section.

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CONTROLS/INSTRUMENTS/ACCESSORIES

OPTIONAL TOOL VALVES (optional) Template Name: OM_1_col Template Date: 1994_04_29

At the end of the boom there is another valve which controls the oil flow for optional tools requiring low flow.

2

IMPORTANT : Never use these valves without having first contacted your CASE Dealer, otherwise you could damage the machine.

1

IMPORTANT : Consult your CASE Dealer before mounting optional tools.

CK98M042

Located under the right-hand hood, this valve enables oil pressure to be adjusted to suit the type of optional tool being used.

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To increase pressure, turn the valve in direction (2).

To decrease pressure, turn the valve in direction (1).

See “Using optional tools” in the “Operating Instructions” Section.

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CONTROLS/INSTRUMENTS/ACCESSORIES

A24690

CS98M634

Position “O” (open) : In this position, oil is supplied to the tool.

NOTE : It is possible to lock the valves in open position. See “Using optional tools” in the “Operating Instructions” Section.

IMPORTANT : Consult your CASE Dealer before mounting optional tools.

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Located on the end of the dipper, these two valves are used to ensure oil supply to optional tools, for example, hydraulic hammers, etc... These valves have two positions.

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OPTIONAL TOOL SUPPLY VALVES (optional)

Template Name: OM_1_col Template Date: 1994_04_29

CS98M633

Position “S” (closed) : In this position, there is no supply of oil to the tool.

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CONTROLS/INSTRUMENTS/ACCESSORIES

FUEL TANK FILLER PUMP (optional) Template Name: OM_1_col Template Date: 1994_04_29

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WARNING : Never refuel when the engine is running. Never smoke when refuelling.

IMPORTANT : This pump is located under the upperstructure frame righthand side hood and is to be used for fuel only.

STEP 3

1

STEP 1 Park the machine on flat, horizontal ground, stop the engine and remove the starter switch key.

STEP 2 PDF0361

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Measure the height of the drum and place the sight ring (1) on the suction tube at a height slightly lower than that of the drum.

STEP 4

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CK99J003

Remove the filler cap from the fuel tank.

PDF0362

Make sure that the screen on the end of the suction hose is correctly attached and then lower the suction hose into the drum.

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CONTROLS/INSTRUMENTS/ACCESSORIES STEP 5

STEP 9

STEP 6

CK99J003

Put the filler cap back on the fuel tank.

STEP 10 CK99J004

Tilt the switch on the pump to “ON” position. Filling will commence.

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STEP 7 Tilt the switch back to “OFF” position when the fuel tank is full.

STEP 8 Empty the fuel remaining in the hose back into the container and wipe off the excess fuel. Put the suction and delivery hoses back in the front storage box.

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Place the delivery hose in the fuel tank.

CK99J004

Template Name: OM_1_col Template Date: 1994_04_29

NOTE : The pump has a 10 amp fuse.

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113

OPERATING INSTRUCTIONS

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

!

WARNING : Do not attempt to operate this machine unless you have first read and perfectly understood the safety messages and instructions appearing in this manual.

Before operating this machine, be sure to do the following : - Check the level of all fluids (engine oil, hydraulic fluid and coolant) and make sure that the fluids and lubricants are suitable for prevailing conditions. See “Fluids and Lubricants” in the “Lubrication/Filters/Fluids” Section and “Operating the machine in cold weather” in the “Operating Instructions” Section.

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

- Inspect the machine, look for any signs of leakage and check the hoses. Tighten or replace as necessary. See the “Maintenance/Adjustments” Section.

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- Check the track assemblies. See “Tracks” in the “Maintenance/Adjustments” Section.

- Before undertaking any travel or working operations during hours of darkness, make sure the lighting and signalling equipment is fully operative.

- Clean the steps and access handles. Grease, oil, mud or (in winter) ice on the steps and access handles can causes accidents. Make sure they are kept clean at all times.

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- Clean or replace any decals which are illegible. See “Decals” in the “Safety/ Decals/Hand Signals” Section.

- Make sure all lower panels and hoods are properly closed.

- Secure the cab door in either fully closed or fully opened position.

- Remove any obstructions which hinder visibility. Clean the windshield, the rear view mirror and the windows.

- Check that no tools or other items have been left on the machine (be it on the undercarriage or the upperstructure) or in the operator’s compartment.

- Work out a means of convenient escape from the machine (emergency exit via the windshield, the rear window glass) in the event of the cab door being jammed or the machine turning over.

- Make sure nobody is on or under the machine. The operator must be alone on the machine.

- Make sure nobody is standing in the machine working area.

- Find out about current safety measures in use on the work site.

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OPERATING INSTRUCTIONS

MACHINE OPERATION WARNING : Check all controls and safety devices in a safe, open area before starting work.

- When operating the machine, be sure to do the following : - When starting the engine, be sure to use the correct procedure for the prevailing weather conditions. See “Starting the engine”.

- Regularly consult the hourmeter to ensure that all servicing operations are carried out punctually. See “Service intervals”.

- If you use your machine in particularly harsh conditions (dusty or corrosive atmosphere), the servicing intervals should be reduced accordingly.

- See “Run-in period” if the machine is new or if the engine has been reconditioned.

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

Over 57 000 volts : 5 metres.

- When working on a public highway, use standard traffic signs and take into consideration the working range of the upperstructure and its attachments. Local or national regulations stipulate the number, type and location of reflector strips.

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- Locate the position of any underground pipes or conduits before starting work.

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!

- Never operate the working or travel controls unless you are properly seated in the operator’s seat with the seat belt correctly fastened.

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

- Operate all controls gradually to ensure smooth machine operation.

- See “Operating in water” if the machine will be standing in water during use.

- See “Transporting the machine” when driving the machine onto a trailer.

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Template Name: OM_1_col Template Date: 1994_04_29

- Modify your driving to suit the type of work and working conditions. See “Operating Instructions”.

OPERATING INSTRUCTIONS - See “Handling the machine” when it is necessary to lift the machine.

- See “Towing the machine” when it is necessary to tow the machine.

Template Name: OM_1_col Template Date: 1994_04_29

- Whenever load handling operations are to be carried out, it is imperative to adhere strictly to the instructions given in this manual and local legislation. See “Load handling”.

- Never use the attachment for sweeping the ground to level out rubble or push objects (transversal stress on the attachment).

- Avoid running the engine in a confined space. If there is no alternative, proper ventilation must be provided at all times.

- Dust, smoke or mist can reduce visibility and cause an accident. Reduce speed or come to a complete halt until visibility has improved.

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- In the event of an operating problem or failure, move the machine to a safe place, lower the attachment to the ground, with the dipper cylinder rod and the bucket cylinder rod completely retracted or completely extended, stop the engine and remove the starter switch key. Locate the problem, report it if necessary and take the necessary steps to warn others not to attempt to operate the machine.

- Do not stop the engine without taking prevailing weather conditions into consideration. See “Stopping the engine”.

- See “Parking the machine” when you have to park the machine.

- When travelling with the hydraulic breaker (optional), make sure it is not too close and not pointing in the direction of the cab window.

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OPERATING INSTRUCTIONS

RUN-IN PERIOD

During this period : Warm up the engine before using it under load.

Do not run the engine for a long period at idle speed.

Check all instruments frequently.

Check the oil levels and coolant solution level frequently.

During the run-in period, the following checks and servicing operations should be carried out in addition to those specified in the service schedule : AFTER THE FIRST 50 HOURS

Replace the pilot circuit filter, the return filter and the drain filter. See “Hydraulic system” in the “Lubrication/Filters/Fluids” Section.

Check the pad screws are tightened to the correct torque. See “Tracks” in the “Maintenance/Adjustments” Section.

AFTER THE FIRST 250 HOURS

Template Name: OM_1_col Template Date: 1994_04_29

Change the oil in the travel reduction gears. See “Travel reduction gears” in the “Lubrication/Filters/Fluids” Section.

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

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

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OPERATING INSTRUCTIONS

STARTING THE ENGINE Template Name: OM_1_col Template Date: 1994_04_29

NOTE : If the machine has been out of use for some time, see “Starting up after storage” in the “Storage” Section.

STEP 3

NOTE : See “Connecting booster batteries” in the “Electrical system” Section, if you have to start the engine using booster batteries.

STEP 1 Take up position correctly in the operator’s seat with the seat belt correctly fastened. See “Operator’s seat” in the “Controls/Instruments/Accessories” Section.

CK98M014

Turn the engine throttle button to low idle position. In cold weather, leave it in halfway position.

STEP 2 TRIM THIS EDGE

STEP 4

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CK98M009

Leave the control cancellation lever in raised position.

CK98M014

Turn the starter switch key to “ON” position and check the instrument console lamps.

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OPERATING INSTRUCTIONS STEP 5

CS98M629 CS98M629

In cold weather, the pre-heating lamp on the instrument panel comes on and the audible warning device sounds.

CS98M626

Make sure the “Control locking” indicator lamp on the console comes on. If not, press the “Control locking” switch on the left-hand control arm.

CK98M014

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(In cold weather)

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(In cold weather)

IMPORTANT : For a temperature over 5°C, hold the key in 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 thirty seconds. Never hold the key in heat position for more than 30 seconds.

CS98M565

Sound the horn on the left-hand control lever.

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Template Name: OM_1_col Template Date: 1994_04_29

STEP 6

Turn the starter switch key to “HEAT” position.

OPERATING INSTRUCTIONS STEP 7

STEP 8

Template Name: OM_1_col Template Date: 1994_04_29

CK98M014

CK98M010

Turn the key to the “START” position.

Release the key as soon as the engine starts to turn. If the engine stops, wait about a minute and recommence the operation.

Lower the control cancellation lever.

STEP 9

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IMPORTANT : Do not operate the starter motor for more than twenty seconds at one time. Do not operate the starter motor when the engine is running.

IMPORTANT : Once the engine is running, let it warm up until a constant idle speed is obtained.

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CS98M626

Press the control locking switch on the left-hand control arm for all functions to become operational.

IMPORTANT : Frequently check the instrument console whilst the engine is running. See “Engine operation”.

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OPERATING INSTRUCTIONS

IMPORTANT : Normal operating temperature of the hydraulic fluid is between 50°C and 80°C. If the machine is used with the hydraulic fluid at a temperature below 20°C, the damage can be caused.

Engine manual warm-up

Hydraulic oil warm-up

With the engine throttle button a quarter open, start the engine and allow it to run approximately 5 to 10 minutes. Then follow the procedure for bringing the hydraulic fluid up to operating temperature.

Turn the engine throttle button to halfopen position. Operate the bucket control slowly until the bucket is completely closed. Operate the dipper retracting control slowly until the dipper is completely retracted and hold the control in this position for 30 seconds. During this time the temperature of the hydraulic fluid will increase.

After 30 seconds, extend the dipper completely and hold the control in this position a further 30 seconds.

Continue the extending and retracting procedure until the temperature rises.

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After starting the engine and before using the machine, allow the hydraulic fluid to reach a temperature of 20°C.

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BRINGING THE MACHINE UP TO OPERATING TEMPERATURE

Template Name: OM_1_col Template Date: 1994_04_29

Operate the travel and attachment controls three or four times to activate hydraulic fluid circulation.

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OPERATING INSTRUCTIONS

ENGINE OPERATION Stop the engine immediately if one of the following situations occurs :

Template Name: OM_1_col Template Date: 1994_04_29

When the engine has started and before beginning work, the following procedure must be observed : - Let the engine run at idle speed for about five minutes until the engine reaches normal operating temperature.

- Sudden increase or decrease in engine speed.

- Abnormal noise.

- Move the engine throttle button to the maximum speed position.

- Black smoke at the exhaust.

- The oil pressure warning lamp coming on during engine operation.

Once normal operating temperature has been reached, check the following : - The exhaust smoke is normal.

- There is no abnormal noise or vibration.

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- There are no oil, fuel or water leaks.

The engine should be run at full speed when operating conditions permit.

The operating speed of the machine and of the attachment should be controlled by means of the control levers.

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Check the instrument console regularly.

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OPERATING INSTRUCTIONS

OPERATING THE MACHINE IN COLD WEATHER Follow the recommendations made below :

Batteries Fuel

Engine oil

b) To prevent crystals forming at -2°C, use fuel which is rated for the ambient temperature or add an appropriate antifreeze to the fuel. See “Fluids and lubricants”, in the “Lubrication/Filters/Fluids” Section.

It should be of the right viscosity for the ambient temperature. See “Fluids and lubricants” in the “Lubrication/Filters/ Fluids” Section.

Hydraulic fluid The viscosity must correspond to the ambient temperature conditions. See “Fluids and lubricants” in the “Lubrication/ Filters/Fluids” Section.

Coolant solution It should be suitable for the ambient temperature and contain a minimum of 50% ethylene glycol solution. See “Fluids and lubricants” in the “Lubrication/Filters/ Fluids” Section.

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a) To prevent condensation forming and water getting into the fuel system, fill the fuel tank after each day’s work and drain off any water before starting the next day’s work.

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They should be fully charged.

OPERATING THE MACHINE IN HOT WEATHER 1.

Keep the coolant at the correct level in the coolant reservoir and in the radiator.

2.

Use the correct solution of ethylene glycol and water in the cooling system.

3.

Test the radiator cap before hot weather starts. Replace the cap as required.

4.

Clean all dirt and debris from the radiator, cooler and engine area.

5.

Check the condition of the fan drive belt.

6.

Check the dust valve in the air cleaner frequently during extreme dust conditions.

7.

Use lubricants of the correct viscosity. See “Fluids and lubricants” in the “Lubrication/Filters/Fluids” Section.

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Template Name: OM_1_col Template Date: 1994_04_29

Follow the recommendations made below :

OPERATING INSTRUCTIONS

STOPPING THE ENGINE STEP 1

STEP 3

Template Name: OM_1_col Template Date: 1994_04_29

CS98M626

CK98M014

Press the control locking switch and the upperstructure swing locking switch on the left-hand control arm to make all machine functions inoperational.

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

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IMPORTANT : When the engine is to be shut down for a considerable length of time, see “Parking the machine”.

STEP 2

In the event of an emergency

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CK98M014

Turn the engine throttle button to low idle position and let the engine run for a minute or so.

CS98M626

IMPORTANT : In cold weather, let the engine run for about five minutes at idle speed.

In the event of an emergency, or if it is not possible to stop the engine using the contact switch key, press the emergency shut-down switch on the left-hand control arm.

IMPORTANT : Always let the engine run at idle before switching off completely, except in emergency situations.

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OPERATING INSTRUCTIONS

MACHINE OPERATION

Watch carefully and make sure you are aware of places where other people are working in your work area. Keep all other people away from the machine. Serious injury can result if these instructions are not followed.

Do not work close to a live overhead electric cable without first making sure that the following minimum distances are respected : Under 57 000 volts : 3 metres.

Over 57 000 volts : 5 metres.

Take note of the locations of pipes/cables before starting work. Electrical cables, gas and water pipes and other underground installations can cause serious injury.

Never hit or push material with the sides of the bucket.

Never sweep the ground with the bucket to level rubble.

When operating the control levers, a whistling sound will be heard if the control lever is held in position while the corresponding cylinder is at the end of its stroke. In this case release the control lever.

On steeply sloping ground, keep engine at maximum speed.

When traveling at right angles to the slope, move on to the slope at low speed.

Never reduce engine speed when traveling down slopes.

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

The following operations are likely to damage the machine. You are therefore advised to avoid them : Excavation using the weight of the machine as a force of impact.

Excavation using the machine’s travel force.

If earth or mud stays stuck inside the bucket, open and close the bucket several times so as to loosen the earth or the mud.

After work, remove any mud and clean the machine.

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Template Name: OM_1_col Template Date: 1994_04_29

Modify your driving to suit working conditions (sloping or rough ground), the nature of the ground and weather conditions.

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!

WARNING : Follow the operating instructions listed in this chapter. Any other practice which has not received the prior approval of the manufacturer is considered to be strictly forbidden.

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Operating instructions

OPERATING INSTRUCTIONS

Operation

When using the attachment, take care not to hit the dozer blade with the bucket.

Template Name: OM_1_col Template Date: 1994_04_29

Take care not to hit the dozer blade against rocks.

Take up position in the operator’s seat and adjust it so that all the controls are readily accessible. See “Operator’s seat” in the “Controls/ Instruments/Accessories” Section.

Then fasten your safety belt.

2.

Make sure the cab door is firmly latched in open or closed position.

3.

Start the engine, taking into consideration the prevailing weather conditions. See “Starting the engine”.

4.

Check all instruments are operating correctly.

5.

Sound the horn.

6.

Lower the control cancellation lever.

7.

Press the control locking switch and the upperstructure swing locking switch to make all machine functions operational once more. See items 4 and 5 under “Left-hand control arm” in the “Controls/Instruments/Accessories” Section.

8.

Try out all the controls in a safe, open area.

When using the upperstructure swing, never change the direction of swing too suddenly.

If the use of the dozer blade is not required, make sure that it is always in the maximum raised position.

When carrying out back-filling operations, operate the two travel levers with the lefthand, while manipulating the dozer blade control lever with the right-hand.

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1.

When climbing up a slope, place the bucket about 40 cm above the ground. When traveling down a slope it is recommended to place the bucket on the ground to prevent the machine from sliding.

Avoid turning the machine on steep slopes.

Never swing the upperstructure on slopes of 15° in the direction of travel or 10° at right angles to the direction of travel.

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OPERATING INSTRUCTIONS

!

WARNING : In the normal travel position, the operator’s compartment is above the idler wheels and the travel reduction gears are to the rear of the upperstructure. If the upperstructure is turned 180° in relation to the undercarriage, lever functions are reversed.

Traveling in a straight line (in reverse)

IMPORTANT : Before undertaking any travel, raise the attachment and the dozer blade.

Traveling in a straight line (forwards) CS98M547

Template Name: OM_1_col Template Date: 1994_04_29

Press the two pedals (or push the two levers) rearwards at the same time.

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NOTE : Travel speed depends on the tilting angle of the travel control levers and pedals and the speed travel mode selected. See “Travel speed selector pedal” in the “Controls/Instruments/Accessories” Section.

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MACHINE TRAVEL

CS98M546

Press the two pedals (or push the two levers) forwards at the same time.

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OPERATING INSTRUCTIONS

Turning to the left (forwards)

Turning to the left (in reverse)

Template Name: OM_1_col Template Date: 1994_04_29

CS98M548

CS98M549

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Simply press the right-hand pedal (or push the right-hand lever) forwards.

Simply press the right-hand pedal (or push the right-hand lever) rearwards.

Turning to the right (forwards)

Turning to the right (in reverse)

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CS98M551

CS98M550

Simply press the left-hand pedal (or push the left-hand lever) forwards.

Simply press the left-hand pedal (or push the left-hand lever) rearwards.

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OPERATING INSTRUCTIONS

Gradual turn on the move

CS98M545 CS98M552

Press the left-hand pedal (or push the left-hand lever) forwards and at the same time press the right-hand pedal (or push the right-hand lever) rearwards.

Coming to a halt

Turning on the spot, to the left

Template Name: OM_1_col Template Date: 1994_04_29

To come to a complete halt, simply release the levers or pedals and they will return to neutral.

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Press one of the pedals (or push one of the levers) and, at the same time, press the other pedal (or push the other lever) in the same direction, but slightly harder.

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Turning on the spot, to the right

CS98M553

Press the right-hand pedal (or push the right-hand lever) forwards and at the same time press the left-hand pedal (or push the left-hand lever) rearwards.

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OPERATING INSTRUCTIONS

TRANSPORTING THE MACHINE By rail Template Name: OM_1_col Template Date: 1994_04_29

Since transport by rail is subject to special regulations, consult an approved organization.

On a trailer

!

WARNING : This machine could slip and fall from a trailer or ramp and cause serious injury. Make sure the trailer and ramps are clean. The machine should be in line with the trailer before being loaded.

Make sure you know the safety rules and regulations before transporting the machine.

Make sure both trailer and machine are fitted with the right safety equipment.

Loading 2 TRIM THIS EDGE

4

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A

1

3 CS98M558

1.

Make sure the trailer is on flat and level ground.

2.

Place blocks (1) in front of and behind the trailer wheels.

3.

4.

Raise the dozer blade (4) and align the machine correctly with the ramps.

5.

Select low travel speed and drive the machine slowly onto the trailer.

Put the access ramps (2) and (3) firmly in place, at an angle (A) of less than 15°.

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OPERATING INSTRUCTIONS

9

8

6 CS98M559

When the machine is completely on the trailer, swing the upperstructure to the rear, so as to bring the attachment round to the access ramp side.

Make sure the attachment is in line with the rear part of the trailer and then bring the machine right to the front of the trailer.

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

Unloading 1.

Carry out Steps 1 to 3 of “Loading”.

2.

Remove the retaining blocks and chains.

3.

Start the engine.

4.

Use the controls on the left-hand control arm to unlock the attachment and swing functions.

5.

Lower the control cancellation lever.

6.

Raise the dozer blade and the attachment to bring the bucket a few centimetres above the floor of the truck or trailer.

10. Stop the engine, remove the starter switch key and raise the control cancellation lever.

7.

More slowly forward, raising the attachment so as to keep it a few centimetres above the ramps.

11. Get out of the cab, lock the door and make sure that the hoods are properly closed.

IMPORTANT : In this position, the travel controls are reversed.

7.

8.

9.

Retract the bucket and the dipper, place a wooden block (5) directly below and then lower the boom until the attachment is resting on the wooden block.

Place a wooden block (6) below the dozer blade and then lower the dozer blade onto the block.

Use the controls on the left-hand control arm to lock the attachment and swing functions.

12. Place rubber blocks (7) at the front and rear of each track.

13. Use chains (8) and blocks (9) to hold down the machine.

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6.

Template Name: OM_1_col Template Date: 1994_04_29

5

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7

8

OPERATING INSTRUCTIONS

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

Never handle the machine without contacting your CASE Dealer before hand. Your CASE Dealer will provide you with the correct procedure to be followed to ensure the operation is carried out in perfect safety.

IMPORTANT : Before handling the machine, make sure the slings are in perfect condition and that they are capable of supporting the weight of the machine. See “Weights” in the “Specifications” Section.

IMPORTANT : It is imperative to use the sling points indicated on the machine decals.

See “Decals” in the “Safety/Decals/Hand Signals” Section.

!

WARNING : The machine must be handled very slowly and horizontally.

!

WARNING : Make sure that there is nobody under or near the machine while it is being handled.

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OPERATING INSTRUCTIONS

!

WARNING : Whenever load handling operations are to be carried out, it is imperative to adhere strictly to the instructions given in this manual and local legislation.

For all handling operations (tubes, concrete pipe connections, shoring material, etc...) the machine must be equipped with safety valves, an overload indicator, a load attachment point and a load chart corresponding to the type of machine and to its attachments.

IMPORTANT : No system or device may be substituted for safety valves when load handling.

When handling loads, make sure you do the following :

- Use only the load fixing point (eye on the bucket connecting rod). See “Load handling eye” in the “Controls/Instruments/Accessories” Section. It is strictly forbidden to weld hooks or lugs to the bottom plate of buckets.

- Use slings and chains in perfect condition, suitable for lifting the load to be handled and fitted with a safety device to prevent accidental opening.

- Check that the safety valves function correctly. The pressure setting should be checked every 6 months according to the manufacturer’s instructions. Consult your CASE Dealer.

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- Park the machine on flat, firm, level ground.

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LOAD HANDLING

- Check that the load handling chart is in the jacket provided for it and that it corresponds to the machine version and its attachment.

- Do not exceed, in any circumstances, the limits shown on the load handling chart. To obtain a load handling chart, consult your CASE Dealer, giving the machine type and model number, the weight of the counterweight, the length and type of boom and dipper.

- Do not allow anyone within the machine’s operating radius.

- Operate the controls smoothly to ensure precise movement of the attachment and the machine.

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Template Name: OM_1_col Template Date: 1994_04_29

- Place the control on the left-hand control arm in “ON” position. This is mandatory.

See “Left-hand control arm” (item 11) in the “Controls/Instruments/Accessories” Section.

OPERATING INSTRUCTIONS Stabilize the load a few centimeters above the ground to make sure it is perfectly balanced before trying to move it.

Template Name: OM_1_col Template Date: 1994_04_29

All movements must be sure and smooth. Moving quickly does not mean moving roughly.

When traveling with a load, make sure you do the following : - Place the upperstructure in line with the undercarriage.

- Bring the load as close as possible to the undercarriage and the ground.

- Be sure all travel is undertaken in slow speed only.

LOAD HANDLING CHART The load handling chart shows the various permitted loads which can be lifted at the various reaches depending on the attachment installed on the machine. See “Maximum loads” in the “Specifications” Section.

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

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The loads are given in daN (1 daN = 1.02 kg), for a machine without tool, with the bucket cylinder rod completely retracted, at 360° upperstructure swing, with a safety factor : - of 33% on stability, - of 15% on the hydraulic limit,

CS99J507

The load fixing point is the eye on the bucket connecting rod. See “Load handling eye” in the “Controls/Instruments/Accessories” Section.

The reach is given from the swing axis of the machine and the height is taken from the load fixing point.

NOTE : The loads given are valid for the total working range height at the reach point indicated.

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OPERATING INSTRUCTIONS

CS98M556

Make sure that the bottom of the stream, or stretch of water in which you will work, can support the weight of the machine.

3.

Before working in water, grease the attachment linkage, turntable bearing and turntable bearing teeth generously.

2.

Only the undercarriage must be below water level. The water may come up to the top of the tracks but no higher.

IMPORTANT : Do not operate in a fast flowing stream.

Template Name: OM_1_col Template Date: 1994_04_29

IMPORTANT : Never work in water if the water level is higher than the tracks.

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1.

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OPERATING THE MACHINE IN WATER

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OPERATING INSTRUCTIONS

OPERATING THE MACHINE ON SLOPING GROUND Template Name: OM_1_col Template Date: 1994_04_29

!

WARNING : Hillside operations can be dangerous. Rain, snow, ice, loose gravel, soft ground, etc... modify terrain conditions. It is up to you to decide if the machine can be used in perfect safety.

- During hillside operations, be extra careful.

- Make sure the upperstructure swing is in locked position and that low travel speed is selected.

- When digging on a slope, avoid swinging the upperstructure towards the bottom of the slope with the backhoe bucket full. Always keep the travel reduction gears pointing down towards the bottom of the slope.

- Always travel in the same direction as the slope, to prevent the machine from turning over.

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OPERATING INSTRUCTIONS

OPERATING THE BACKHOE BUCKET Fill the backhoe bucket by maneuvering the 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.

Excavating method

PDH0494M

WRONG

WRONG

The backhoe bucket will dig in and cause a stall.

The bucket is pushed upwards. This will also increase the cycle time.

Template Name: OM_1_col Template Date: 1994_04_29

CORRECT

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PDH0493M

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Filling

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OPERATING INSTRUCTIONS

QUICK IMPLEMENT INSTALLATION AND REMOVAL (optional) Template Name: OM_1_col Template Date: 1994_04_29

!

WARNING : Never put your hands inside the quick coupler if the engine is running.

Assembly STEP 1

STEP 4

2

1

1

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CK99G002

CK99H001

Install the quick coupler on the dipper and on the connecting rod using the CASE pins (1) supplied and connect the hydraulic connections.

Operate the dipper control lever so as to bring the quick coupler hook (1) around the tool pin (2).

STEP 5

STEP 2

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Make sure that the tool to be installed is in a safe position on flat, level ground and is equipped with its CASE genuine pins.

STEP 3

CK99G001

Place the switch in the unlocked position.

See “Quick coupler locking and unlocking control switch” in the “Controls/Instruments/Accessories” Section.

CK97A009

Remove the safety shaft and the locking pin.

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OPERATING INSTRUCTIONS

CK99H002

CK99G001

STEP 7

Place the switch in the locked position.

See “Quick coupler locking and unlocking control switch” in the “Controls/Instruments/Accessories” Section.

IMPORTANT : Check that the quick coupler is correctly engaged on the tool pins STEP 9

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Operate the bucket control lever so that the pin is completely engaged in the quick coupler hook.

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STEP 8

STEP 6

CS99G514

CK99H003

Install the safety shaft and locking pin.

IMPORTANT : It is essential that the safety shaft and locking pin are in place.

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Template Name: OM_1_col Template Date: 1994_04_29

Raise the dipper and retract the bucket until the teeth are in the vertical position.

OPERATING INSTRUCTIONS

Disassembly

STEP 4

STEP 1

Template Name: OM_1_col Template Date: 1994_04_29

Place the tool on flat, level ground.

STEP 2

CK99H002

Wait five to ten seconds to enable the the hook to retract. Operate the bucket control lever so as to disengage the shaft.

STEP 5

CK99H003

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Remove the locking pin and the safety shaft.

STEP 3

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CK99H001

Operate the dipper control lever so as to unhook the bucket.

CK99G001

Place the switch in the unlocked position.

See “Quick coupler locking and unlocking control switch” in the “Controls/Instruments/Accessories” Section.

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OPERATING INSTRUCTIONS

PARKING THE MACHINE Place the machine on flat, level ground, away from soft ground excavations and badly shored cavities.

STEP 2 Place the upperstructure frame in line with the undercarriage, retract the attachment and dig the bucket into the ground to anchor it. Then lower the dozer blade to the ground.

STEP 3

CS98M626

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Use the control locking switch on the lefthand control arm to lock the controls and make sure the locking indicator lamp lights up on the instrument console.

STEP 5

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STEP 4

STEP 1

CS98M626

Use the upperstructure swing locking switch on the left-hand control arm to lock the upperstructure and make sure the locking indicator lamp lights up on the instrument panel.

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Template Name: OM_1_col Template Date: 1994_04_29

CK98M014

Turn the engine throttle button to low idle position and let the engine run for approximately five minutes.

OPERATING INSTRUCTIONS STEP 8

STEP 6

Template Name: OM_1_col Template Date: 1994_04_29

CK98M014

A23949

Stop the engine and remove the starter switch key.

STEP 7

Lock the operator’s compartment door and check that all hoods and lower panels are correctly fastened.

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IMPORTANT : Check that the no part of the machine is encroaching on the highway. If this cannot be avoided, set up approved traffic signs.

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CK98M009

Raise the control cancellation lever and get out of the operator’s compartment.

!

ATTENTION : Never jump down from the machine. When alighting from the operator’s compartment, or from the upperstructure, always face the machine and use the steps and access handles.

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OPERATING INSTRUCTIONS

First of all, make sure that it can be towed without causing additional damage.

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

!

WARNING : Towing is a delicate maneuver which is always carried out at the risk of the user.

The manufacturer’s warranty does not apply to incidents or accidents which occur during towing. Where possible, carry out the repairs at the site.

!

WARNING : The machine must be towed very slowly, over a short distance and only if it is really unavoidable.

!

WARNING : It is mandatory that a towing bar be used for any towing operation.

!

WARNING : The operator must be the only person on the machine when towing. Make sure that nobody else is on the machine or within its working range.

CD99B001

Use this hole for towing the machine.

Template Name: OM_1_col Template Date: 1994_04_29

!

WARNING : It is forbidden to use this hole for towing another machine.

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IMPORTANT : The machine should only be towed when it can not be driven.

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TOWING THE MACHINE

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OPERATING INSTRUCTIONS

USING OPTIONAL TOOLS (optional) Template Name: OM_1_col Template Date: 1994_04_29

IMPORTANT : Consult your CASE Dealer before mounting optional tools.

STEP 2

2

STEP 1

1 3

CS98M635

4

A24690

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CS98M636

CS98M634

Using a hexagonal wrench, place the supply valves in “O” (open) position.

To lock the valves, remove the snap ring (2), remove the locking plate (1) and install it so the notch (3) is on the locking pin (4). Then install the snap ring (2).

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OPERATING INSTRUCTIONS

IMPORTANT : Never operate the valve without first having contacted your CASE Dealer.

STEP 4

NOTE : When removing the optional tool, place the supply valves in “S” (Shut) and then lock them in position, following the procedure explained in Step 2.

CP99A002

Place the switch on the left-hand control arm in “ON” position.

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Template Name: OM_1_col Template Date: 1994_04_29

CK98M012

Use the pedal to operate the optional tool.

Press the pedal forward for tools requiring single flow (hydraulic hammers).

Press the pedal forward or rearward for tools requiring double flow (concrete crushers). See “Auxiliary hydraulic circuit” to select the type of hydraulic circuit to be used with the optional tool.

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CK98M042

Consult your CASE Dealer for instructions on how to select the correct pressure for the optional tool.

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STEP 5

STEP 3

OPERATING INSTRUCTIONS

AUXILIARY HYDRAULIC CIRCUITS Template Name: OM_1_col Template Date: 1994_04_29

Your machine can have one of two auxiliary hydraulic circuits. One circuit is for single acting, continuous flow equipment, such as hydraulic hammers. The second circuit is for single acting, or double acting continuous, or double acting intermittent flow equipment, such as concrete crushers. The circuit configurations are as follows:

Hydraulic hammer configuration 1

3

2

1 2

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CK98M042

1.

CS99B528

CS99B526

Place the supply valve (1) in open (O) position.

2. Place the supply valve (2) on the flow selector in the position shown. The line on the supply valve shows the flow direction.

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3. Make sure that the pressure of the main relief valve (3) has correctly been adjusted by your CASE Dealer to suit the working pressure of the hydraulic hammer.

IMPORTANT : Never change the setting of the main relief valve (3) without first consulting your CASE Dealer.

4.

See “Using optional tools”.

NOTE : For normal work (digging), supply valve (1) should be in closed (S) position.

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OPERATING INSTRUCTIONS

Concrete crusher configuration 2

1 2

CK98M042

1.

CS99B529

CS99B527

Place the supply valve (1) in closed (S) position.

3. Make sure that the pressure of the main relief valve (3) has correctly been adjusted by your CASE Dealer to suit the working pressure of the concrete crusher.

IMPORTANT : Never change the setting of the main relief valve (3) without first consulting your CASE Dealer.

4.

See “Using optional tools”.

Template Name: OM_1_col Template Date: 1994_04_29

NOTE : For normal work (digging), supply valve (1) should be in closed (S) position.

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2. Place the supply valve (2) on the flow selector in the position shown. The line of the supply valve shows the flow direction.

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1

3

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OPERATING INSTRUCTIONS

HANDLING THE HYDRAULIC BREAKER (optional) Template Name: OM_1_col Template Date: 1994_04_29

The lifting equipment must be strong enough to take the weight of the hydraulic breaker. See “Hydraulic breaker” in the “Specifications” Section.

CS99C626

- Use slings, belts, fittings and chains which are in perfect condition and which are equipped with safety type hooks that will not accidentally open.

- Use a means of guidance while handling and use handling equipment which is conformance with regulations.

- Do not allow anyone to remain within the working range of the hydraulic breaker while it is being handled.

- Attach the slings and chains as shown below.

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BREAKING TECHNIQUES ON A HYDRAULIC BREAKER (optional) To increase the hydraulic breaker’s working life, pay particular attention to correct working methods and to the correct choice of tool for the job. There are essentially two ways of breaking with a hydraulic breaker.

Breaking by penetration (or cutting)

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In this form of breaking a moil point or chisel tool is forced inside the material. This method is most effective in soft, layered or plastic, low abrasive material. The high impact rate of the small breakers makes them ideal for penetrative breaking.

Breaking by impact With impact breaking, the material is broken by transferring very strong mechanical stress waves from the tool into the material. The best possible energy transfer between the tool and the object is achieved with a blunt tool.

Impact breaking is most effective in hard, brittle and very abrasive materials. The use of a chisel tool in hard material will cause the sharp edge to wear very quickly. The high impact energy of the big breakers makes them ideal for impact breaking.

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OPERATING INSTRUCTIONS

Chisel and moil

Spade tool

- For sedimentary (e.g. sandstone) and weak metamorphic rock into which the tool penetrates.

- Concrete.

- Trenching and benching.

- Frozen or compact ground Asphalt.

- For igneous (e.g. granite) and tough metamorphic rock (e.g. gneiss) into which the tool doesn’t penetrate.

- Concrete.

- Breaking boulders.

- Ground compacting It is important to choose a tool, which is suitable for your breaker and for the intended application. The choice of tool depends on the hydraulic breaker model.

See “Hydraulic breaker” in the “Specifications” Section.

Super blunt - When tool wear is extensive in igneous (e.g. granite) and tough metamorphic rock (e.g. gneiss) into which the tool doesn’t penetrate.

- Breaking boulders (very abrasive rock).

- Do not use for penetrative work or in non-abrasive rock.

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Blunt tool

Compacting plate

Template Name: OM_1_col Template Date: 1994_04_29

Selection of standard and special tools to suit each application are available. The correct type of tool must be selected to get the best possible working results and longest life time for the tool. Choosing the best tool type for an application may require some testing. See your CASE Dealer.

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CHOICE OF TOOLS ON A HYDRAULIC BREAKER (optional)

OPERATING INSTRUCTIONS

SPECIAL CONDITIONS OF USE ON A HYDRAULIC BREAKER (optional) Template Name: OM_1_col Template Date: 1994_04_29

If breaker is to be used in conditions that differ from normal breaking or demolition work conditions, listed below, that may require modifications to attachment, special operating techniques, increased maintenance or special wear items.

-

Tunnelling, Foundry cleaning, Underwater operations, Operations in extremely low or high temperatures, Use of special hydraulic fluids, Breaker operations with special attachment (extra long boom etc.), Other special conditions.

In case of special conditions of use, please consult your CASE Dealer.

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Template Name: OM_1_col Template Date: 1994_04_29

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113

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OPERATING INSTRUCTIONS

118

SERVICING INTERVALS

SERVICING INSTRUCTIONS Template Name: OM_1_col Template Date: 1994_04_29

Respect the maintenance intervals by checking the hourmeter every day. Before starting maintenance, park the machine on flat, firm ground, away from any obstacles, with the dipper retracted and the bucket on the ground. Unless otherwise specified, 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. Wear suitable clothing and remember to use the necessary safety equipment.

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

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!

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 if the machine moves without an operator, serious injury can result. Before performing any maintenance, the following steps must be carried out : 1. Park the machine on flat, horizontal ground.

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

3. Lower the dozer blade until it is resting on the ground.

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

5. Lock the tracks to prevent any machine movement.

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When carrying out service work on the machine, place a “Do not operate” tag on the right-hand control arm. Never climb down from the operator’s compartment leaving the engine running.

Any modification to this machine without prior authorization could cause serious injury.

Do not make any modifications without authorization. Consult your CASE Dealer.

IMPORTANT : If you use your machine in particularly harsh conditions (dusty or corrosive atmosphere, etc.), the servicing intervals should be reduced accordingly.

IMPORTANT : Take particular care to replace all filters regularly. Clean filters mean longer engine running life.

IMPORTANT : Oil and fluid should not be thrown on the ground. They must be stored and removed by a company which is responsible for their recycling or their disposal.

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SERVICING INTERVALS

The hourmeter enables service operations to be scheduled. It displays the total time that the engine has been operated, in hours and tenths of an hour.

Servicing intervals are carefully calculated to guarantee safe and efficient machine operation.

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

Template Name: OM_1_col Template Date: 1994_04_29

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CP98M007

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HOURMETER

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SERVICING INTERVALS

118

DRAIN

CHECK

2

GREASE

171 172 118 124 126 128

118 134 118

REPLACE

138 142 149 161 168

SERVICE POINTS Tighten any loose connections hydraulic breaker (optional) Impact hydraulic breaker (optional) Tool shank hydraulic breaker (optional) Tool retainigpins hydraulic breaker (optional) Greasing tool hydraulic breaker (optional) Engine oil level Coolant level Hydraulic reservoir level Idler wheel and rollers Rubber tracks (optional)

INTERVALS IN HOURS CLEAN

Template Name: OM_1_col Template Date: 1994_04_29

P A G E 118

NO OF POINTS

INTERVALS

2

-

2 2 10 10

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1 1 1 2

10 10 10 10 10

Radiator and oil cooler Fan/alternator belt Hydraulic breaker (optional) Dozer blade Monoblock boom/dipper Offset backhoe boom/dipper

1 1 4 6 15

10 10 50

132 133 144 144 174 165

Dipper/backhoe bucket Quick coupler Drain fuel tank sediment Drain water separator Fuel tank filter Track tension

7 1 1 1 1 2

139 141 124 150 158 162

Engine oil (NOTE 1) Cooling circuit hoses/clamps Turntable bearing Drain hydraulic reservoir sediment Primary air filter element Travel reduction gears oil lever

1 3 1 1 2

168 172 195 139 135 145

Pad screw torque (NOTE 3) Fan/alternator belt tension Battery electrolyte level Engine oil filter (NOTE 2) Turntable teeth Fuel filter

1 2 1 1 1

171

Radiator and oil cooler

1

50 50 50 50 50 50 50 50 100 200 200(1) 250 250

250 250 250(2) 400 500 500 500

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250 250 250

Hydraulic breaker (optional) Pilot filter (NOTE 2) Suction filter

1 1

151 152 152

Return filter (NOTE 2) Ultra Clean filter Breather filter

1 1 1

1000 1000 1000

153 157 157

Drain filter (NOTE 2) Air filter primary element Air filter secondary element

1 1 1

1000 1000(3) 1000(4)

163 174 174

Travel reduction gears (NOTE 4) Rocker arm clearance Machine inspection and cleaning

2 1 1

196 197 135

Alternator Starter motor Swing reduction gear

1 1 1

142 151 153

Cooling circuit Suction filter Hydraulic oil

1 1 1

71 188 188

Safety valves Fire extinguisher Air conditioning (optional)

2 1 1

DRAIN

GREASE

600(10) 1000 1000

1000 1000

1000(5) 1000(5) 2000 2000(6) 5000(7) 5000 (8) (9) (9)

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1000(5) 1000

$OW WR KLGH WHPSODWH LQIRUPDWLRQ $OW WR GLVSOD\ WHPSODWH LQIRUPDWLRQ

118 150 151

CHECK

REPLACE

SERVICE POINTS

INTERVALS IN HOURS CLEAN

P A G E

NO OF POINTS

SERVICING INTERVALS

(1) Or every 6 months.

(2) Or whenever the warning lamp lights up on the instrument console.

(3) Or after cleaning 6 times.

(5) Consult your CASE Dealer.

(6) Or every year.

(7) And whenever the hydraulic fluid is replaced.

(8) Have this checked by your CASE Dealer every 6 months.

(9) Have this checked by a specialist every 6 months.

(10) Or once a year, have checked by your CASE Dealer.

NOTE 1 : Change after the first 50 hours during the run-in period.

NOTE 2 : Replace after the first 50 hours during the run-in period.

NOTE 3 : Check after the first 50 hours during the run-in period.

NOTE 4 : Drain after the first 250 hours during the run-in period.

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7HPSODWH 1DPH 20B BFRO 7HPSODWH 'DWH B B

(4) Or after cleaning the primary air filter element 3 times.

SERVICING INTERVALS

HYDRAULIC BREAKER INTERVALS (optional) Maintenance intervals Template Name: OM_1_col Template Date: 1994_04_29

EVERY 2 HOURS 1.

Grease the tool shank and the tool bushing.

2.

Tighten any loose connections.

3.

Check the impact efficiency and evenness of operation.

EVERY 10 HOURS OR AT LEAST ONCE A WEEK

1. Remove the tool retaining pins and check their condition. Grind burrs away if necessary. See “Replacing a tool on a hydraulic breaker” in the “Maintenance/ Adjustments” Section.

2. Check that the tool has received sufficient greasing. Grease more frequently, if necessary.

EVERY 50 HOURS OR AT LEAST ONCE A MONTH TRIM THIS EDGE

IMPORTANT : It is preferable to have the first servicing after 50 hours operation carried out by your CASE Dealer.

1. Check the tool shank and tool bushing for wear. See “Replacing a tool on a hydraulic breaker” in the “Maintenance/Adjustments” Section.

2.

Check the hydraulic hoses. Replace them if necessary.

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3. Make sure the hydraulic breaker moves freely in its housing and that the antivibration components (buffers and pads) are in good condition.

4. Check the condition of the wear plates by moving the hydraulic breaker from one side of the housing the other with a prybar. The maximum acceptable play is approximately 10 mm.

EVERY 600 HOURS OR ONCE A YEAR Have the hydraulic breaker thoroughly checked by your CASE Dealer.

Maintenance intervals Service intervals are considerably shorter for such applications as breaker tunnelling, sealing, foundry cleaning, underwater use, etc. For special applications, consult your CASE Dealer.

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LUBRICATION/FILTERS/FLUIDS

163

FLUIDS AND LUBRICANTS

WARNING : The conditions of use for individual fluids and lubricants must be respected.

Hydraulic fluid

Grease

CASE hydraulic fluid is specially designed for high pressure applications and for the CASE hydraulic system. The type of fluid to be used depends on the ambient temperature.

The type of grease to use depends on ambient temperature.

Temperate and hot climates

Temperate climates

-20°C to +60°C Extreme pressure grease EP NLGI grade 2 with molybdenum disulphide.

-20°C to +40°C Fluid type ISO VG 46

Cold climates -40°C to +20°C Extreme pressure grease EP NLGI grade 0.

Hot climates 0°C to +60°C Fluid type ISO VG 100

Cold climates -40°C to +20°C Fluid type ISO VG 22

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!

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Lubricants must have the correct properties for each application.

Transmission component oil Extreme pressure oil used for enclosed transmission components.

Extreme pressure oil type API GL5 grade 80W90 or ISO VG 150

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Template Name: OM_1_col Template Date: 1994_04_29

These various grades of fluid must be in conformity with CASE France.

LUBRICATION/FILTERS/FLUIDS

Engine oil Template Name: OM_1_col Template Date: 1994_04_29

CASE N°1 motor oil is the oil recommended for your engine. This oil ensures correct lubrication of your engine in all working conditions.

If CASE N°1 Multiperformance or Performance engine oil cannot be obtained, use only oil of the API/CG/CF category.

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 CASE lubricants.

RD97F136

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RB97F100

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LUBRICATION/FILTERS/FLUIDS

A 3

1

4 B CS98M561

Template Name: OM_1_col Template Date: 1994_04_29

(A) Fahrenheit Temperature (B) Celsius Temperature (1) All seasons (2) Winter (3) Tropical (4) Arctic (*) Use of an engine oil heater, or and engine coolant heater is required.

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2

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Oil viscosity/Oil range

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LUBRICATION/FILTERS/FLUIDS

Template Name: OM_1_col Template Date: 1994_04_29

Fuel

Fuel storage

Use fuel which is to ASTM (American Society for Testing and Materials) D975 standard.

Long storage can lead to the accumulation of impurities and condensation in the fuel. Engine trouble can often be traced to the presence of water in the fuel.

Use grade N°2 fuel. The use of other types of fuel can result in a loss of power and may cause high fuel consumption.

When the temperature is very cold, the use of a mixture of N°1 and N°2 fuel is permitted. See your fuel vendor for winter fuel requirements in your area.

If the temperature falls below the fuel cloud point (point at which wax begins to form) the wax crystals will cause power loss or will prevent the engine from starting.

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IMPORTANT : In cold weather, fill the fuel tank at the end of the day’s work, in order to prevent the formation of condensation.

The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible. Drain off water and impurities regularly.

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

For areas where ambient temperature is over -36°C, use a blend of 50% ethyleneglycol based anti-freeze.

For areas where the temperature is below -36°C, it is advisable to use a blend of 40% water and 60% anti-freeze.

ENVIRONMENT

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Before carrying out any maintenance operation on this machine and before disposing of used fluids or lubricants, always think of the environment. Never throw oil or fluid on the ground and never place it in leaking receptacles.

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

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LUBRICATION/FILTERS/FLUIDS

ENGINE Type of oil ............................................................................... CASE N°1 engine oil Capacity .....................................................................................................6.8 litres COOLING SYSTEM Cooling system capacity ..........................................................................10.1 litres FUEL SYSTEM Reservoir capacity.....................................................................................140 litres

Template Name: OM_1_col Template Date: 1994_04_29

TRAVEL REDUCTION GEARS Type of oil ....................................................API GL5 grade 80W90 or ISO VG 150 Capacity (per reduction gear).......................................................................1.7 litre

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HYDRAULIC SYSTEM Type of fluid .............................................................................CASE hydraulic fluid Total system capacity ..................................................................................95 litres Reservoir capacity...................................................................................... 56 litres

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FLUID AND LUBRICANT CAPACITIES AND SPECIFICATIONS

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LUBRICATION/FILTERS/FLUIDS

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

Use the following grease : EP NLGI grade 2 (for temperate and hot climates) -20°C to +60°C EP NLGI grade 0 (for cold climates) -40°C to +20°C

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1

2 3 4

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CS99J502

NOTA : The figures mentioned in brackets show the number of grease points.

Every 50 hours

Every 250 hours

1

2

CP99A007

CK98M032

Dozer blade ...................................(4)

Turntable bearing .......................... (1)

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LUBRICATION/FILTERS/FLUIDS Every 500 hours

CK98M032

Turntable teeth .............................. (1) See “Greasing the turntable teeth”.

Every 2000 hours TRIM THIS EDGE

4

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3

CS98M615

See “Greasing the swing reduction gear”.

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Template Name: OM_1_col Template Date: 1994_04_29

Swing reduction gear .................... (1)

LUBRICATION/FILTERS/FLUIDS

Monoblock boom/Dipper Template Name: OM_1_col Template Date: 1994_04_29

Use the following grease : EP NLGI grade 2 (for temperate and hot climates) -20°C to +60°C EP NLGI grade 0 (for cold climates) -40°C to +20°C

3

4

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1 2

CS99J503

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NOTA : The figures mentioned in brackets show the number of grease points.

Every 50 hours

Every 50 hours

1

2

CK98M030

CK98M030

Boom bottom pin............................(1)

Boom cylinder bottom pin.............. (1)

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LUBRICATION/FILTERS/FLUIDS Every 50 hours

CP98M011

Boom cylinder top pin.................... (1) Dipper cylinder bottom pin............. (1) Every 50 hours

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4

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3

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Template Name: OM_1_col Template Date: 1994_04_29

CP98M010

Dipper/boom linkage ..................... (1) Dipper cylinder top pin .................. (1)

LUBRICATION/FILTERS/FLUIDS

Offset backhoe boom/Dipper Template Name: OM_1_col Template Date: 1994_04_29

Use the following grease : EP NLGI grade 2 (for temperate and hot climates) -20°C to +60°C EP NLGI grade 0 (for cold climates) -40°C to +20°C

4

9 5

6

11 10

8

7

3

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1 2 CS99J504

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NOTA : The figures mentioned in brackets show the number of grease points.

Every 50 hours

Every 50 hours

1

2

CK99J005

CK99J006

Boom bottom pin............................(1)

Boom cylinder bottom pin.............. (1)

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LUBRICATION/FILTERS/FLUIDS Every 50 hours

Every 50 hours

6

CK99J007

CK99J010

Boom cylinder top pin.................... (1)

Offset cylinder top pin.................... (1)

Every 50 hours

Every 50 hours

7 TRIM THIS EDGE

4

CK99J011

Dipper cylinder .............................. (3)

Offset linkage bottom pin ............... (1)

Every 50 hours

Every 50 hours

5

8

CK99J009

CK99J012

Offset cylinder bottom pin.............. (1)

Offset linkage top pin..................... (1)

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Template Name: OM_1_col Template Date: 1994_04_29

CK99J008

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3

LUBRICATION/FILTERS/FLUIDS Every 50 hours

Every 50 hours

9

11

Template Name: OM_1_col Template Date: 1994_04_29

CK99J013

CK99J015

Boom/mobile section articulation pin ...........................(2)

Offset/dipper articulation pin ......... (1)

Every 50 hours

10 TRIM THIS EDGE

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CK99J014

Mobile section/ offset articulation pin ..................(2)

130

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LUBRICATION/FILTERS/FLUIDS

LUBRICATION/FILTERS/FLUIDS

Dipper/Backhoe bucket Template Name: OM_1_col Template Date: 1994_04_29

Use the following grease : EP NLGI grade 2 (for temperate and hot climates) -20°C to +60°C EP NLGI grade 0 (for cold climates) -40°C to +20°C

1 2

2 TRIM THIS EDGE

CS99J505

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NOTA : The figures mentioned in brackets show the number of grease points.

Every 50 hours

Every 50 hours

1

1

CP98M010

CK99J016

Bucket cylinder bottom pin (monoblock boom) .....................(1)

Bucket cylinder bottom pin (offset backhoe boom) .............. (1)

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LUBRICATION/FILTERS/FLUIDS Every 50 hours

Use the following grease : EP NLGI grade 2 (for temperate and hot climates) -20°C to +60°C EP NLGI grade 0 (for cold climates) -40°C to +20°C NOTA : The figures mentioned in brackets show the number of grease points.

Every 50 hours

CK99H003

Quick coupler ................................ (1)

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Quick coupler

Template Name: OM_1_col Template Date: 1994_04_29

CK99J002

Bucket lingage .............................. (6)

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2

LUBRICATION/FILTERS/FLUIDS

GREASING THE HYDRAULIC BREAKER (optional) Template Name: OM_1_col Template Date: 1994_04_29

Greasing intervals

Correct greasing

1.

The tool shank must be well lubricated before installing.

2.

Press the grease gun between 5 to 10 times, at regular intervals, to grease the tool bushing and the tool.

While greasing, the hydraulic breaker must be standing upright resting on the tool to ensure that the grease will penetrate downwards between the tool and the bushing.

3.

Adapt the intervals and the quantity of grease to the wear rate of the tool and to working conditions. This can be anything between every two hours and once a day, depending on the type of material (rock/concrete) being broken.

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Insufficient greasing or improper grease may cause :

• •

Abnormal wear of tool bushing and tool Tool breakage

Do not fill the space between the piston and the tool with grease. A lower piston seal failure can result and the hydraulic breaker will eventually leak oil.

Grease points Use the following grease: - EP NLGI grade 2 (for temperate and hot climates) -20°C to +60°C - EP NLGI grade 0 (for cold climates) -40°C to +20°C Every 2 hours

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CP99C004

Tool shank......................................... (1) Tool bushing...................................... (1) NOTE : The figures mentioned in brackets show the number of grease points.

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LUBRICATION/FILTERS/FLUIDS

Every 500 hours, remove inspection cover (1) and visually check for damage and the condition of the gear surface.

2.

If the gear surface is not well greased, add grease.

3.

If the grease is white due to moisture content, etc. replace it with new grease.

4.

If the presence of water is detected, remove the grease discharge plug (2) and drain off the water.

- Remove the protective cover from the lower, central area.

- Remove the grease discharge plug (2) from underneath the machine.

- Discharge the water or cloudy grease.

- Install the discharge plug (2).

- Insert new grease through the port (3) and install the inspection cover (1).

2 3 CS98M608

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1

1.

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GREASING THE TURNTABLE TEETH

Every 2000 hours, remove the air bleed plug (1) and refill with grease through the greasing port (2). A certain amount of grease should run out a little from the air bleed plug (1).

1

IMPORTANT : When greasing, if the air bleed plug (1) is not removed, the inner seal will be damaged.

2 CS98M615

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Template Name: OM_1_col Template Date: 1994_04_29

GREASING THE SWING REDUCTION GEAR

LUBRICATION/FILTERS/FLUIDS

LEVELS Every 10 hours

Every 10 hours

Template Name: OM_1_col Template Date: 1994_04_29

CK98M024

CK98M023

Engine oil.......................................(1)

Hydraulic reservoir ........................ (1)

Every 10 hours

Every 250 hours

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CK98M019

CP99A008

Coolant solution expansion reservoir ....................................(1) ETHYLENE GLYCOL and WATER

Travel reduction gears .................. (2) Type API GL5 grade 80W90 or ISO VG 150

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A24643

Batteries ....................................... (2)

Template Name: OM_1_col Template Date: 1994_04_29

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

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Every 250 hours

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

Engine oil level check .................................................Every 10 hours or every day Oil change ..................................................................................... Every 200 hours (After the first 50 hours of operation) Oil filter replacement ..................................................................... Every 400 hours (After the first 50 hours of operation) Oil type ..........................................................................See “Fluids and lubricants” Oil capacity ................................................................................................ 6.8 litres

Level STEP 3

STEP 1 Park the machine on flat, horizontal ground. Stop the engine and remove the starter switch key.

B

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STEP 2

A

CS98M579

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CK98M024

When the engine has been stopped for fifteen minutes, remove the dipstick, wipe it with a clean cloth and replace it in the guide tube as far as it will go. Then take it out again.

CK98M024

If the oil level is below the mark (A) (minimum), remove the oil filler cap, add oil up to the mark (B) (maximum) on the dipstick and then replace the oil filler cap.

NOTE : The level should not be higher than the mark (B) (maximum) on the dipstick.

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Engine oil change and oil filter replacement

STEP 5

STEP 1 Park the machine on flat, horizontal ground, stop the engine and remove the starter switch key.

STEP 2

CK98M025

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Clean the area around the oil filter and remove it, using a filter wrench.

STEP 6

CK98M024

Remove the oil filler cap.

STEP 3

PH08325

Coat the seal of new filter with a fine film of oil.

CS98M580

Place a receptacle of a suitable capacity under the engine sump drain plug, remove the plug and allow the oil to flow out.

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Template Name: OM_1_col Template Date: 1994_04_29

NOTE : Change the oil while the engine is still warm. The oil will flow more easily.

Install a new seal on the drain plug and install and tighten the plug.

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STEP 4

LUBRICATION/FILTERS/FLUIDS

Template Name: OM_1_col Template Date: 1994_04_29

STEP 7

STEP 9

Install the new filter, tightening until the seal comes into contact with the filter head, then tighten a further half-turn by hand.

Run the engine for a few minutes and check that there are no leaks. Check the oil level again and add more oil if necessary.

IMPORTANT : Do not use the filter wrench to install the filter, as overtightening can damage the seal and the filter.

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

STEP 8

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CK98M024

Fill the engine with new engine oil (6.8 litres). Install the oil filler cap.

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LUBRICATION/FILTERS/FLUIDS

COOLING SYSTEM

!

WARNING : 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.

!

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

Coolant solution Put only ethylene-glycol coolant solution in the cooling system. Use good quality ethylene-glycol that has a high boiling point, with no additives to prevent leakage. Do not use non-approved 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.

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Coolant reservoir level check .......................................................... Every 10 hours or every day Cooling system hose and clamp tightness check ......................... Every 200 hours or every six months Coolant solution change........................................ Every 2000 hours or every year System capacity .......................................................................................10.1 litres

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Service specifications

Template Name: OM_1_col Template Date: 1994_04_29

Consult your CASE Dealer for suitable coolant solution.

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Level Template Name: OM_1_col Template Date: 1994_04_29

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

!

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

STEP 2

1

2

CK98M019

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On flat, level ground, before using the machine, (while the engine is still cold), the level in the coolant reservoir should be between the “FULL” (1) and “LOW” (2) marks. If not, see “Filling”.

CS98M616

Open the radiator drain valve.

Draining

NOTE : Have a receptacle of a suitable capacity ready.

STEP 1

STEP 3

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CK98M021

Remove the radiator cap.

CS98M580

Remove the drain plug located on the engine block.

NOTE : Have a receptacle of a suitable capacity ready.

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Rinse the radiator and the expansion reservoir with clean water.

STEP 5 Close the drain valve when the radiator is completely empty. Install the drain plug on the engine block. Fill it again.

Filling STEP 1 CK98M019

Fill the expansion reservoir to the “FULL” mark and install the cap.

IMPORTANT : Use the correct coolant solution.

Run the engine at idle speed for about five minutes. Add coolant solution if the level in the expansion reservoir drops.

CK98M021

IMPORTANT : Do not fill the expansion reservoir above the “FULL” mark.

Template Name: OM_1_col Template Date: 1994_04_29

Fill with coolant solution via the radiator until overflowing and install the radiator cap.

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STEP 3

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STEP 2

STEP 4

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

Draining water and sediment from the fuel tank.............................. Every 50 hours Draining water from the water separator......................................... Every 50 hours Fuel filter replacement .................................................................. Every 500 hours Fuel tank capacity ..................................................................................... 140 litres Type of fuel ...................................................................See “Fluids and lubricants”

Draining water and sediment from the fuel tank

Draining water from the water separator

2

A

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1 CK98M033 CS98M614

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Have a container ready to collect the drained contaminants.

Open the drain valve located at the bottom of the tank and drain the accumulated sediment and water.

After draining, close the drain valve.

When the float reaches the level line (A) Loosen the drain plug (1) and drain the water and sediment.

When the float (2) settles on the bottom, tighten the drain plug (1).

Verify that there are no fuel leaks.

!

WARNING : Completely wipe off any spilt fuel. It may cause a fire.

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Bleeding the system 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.

CK98M026

Clean the area around the filter head.

2

Apply a thin coat of oil or grease on the new filter seal.

NOTE : Do not fill the new filter with fuel before installing.

CK98M026

Install the new filter. Turn the filter until the seal comes into contact with the filter head and turn an extra half turn by hand.

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1

Place a receptacle of a suitable capacity under the filter and remove the filter, using a filter wrench.

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Replacing the fuel filter

NOTE : If the engine does not regain full power after replacing the filter, bleed the system.

CS98M578

Loosen the knob of the priming pump (2).

Loosen the air bleed screw (1). Move the handle of the priming pump (2) up and down until no bubbles come out of the air bleed screw (1).

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Template Name: OM_1_col Template Date: 1994_04_29

IMPORTANT : Do not use a filter wrench to install the filter. Overtightening the filter can damage the seal and filter.

LUBRICATION/FILTERS/FLUIDS

Template Name: OM_1_col Template Date: 1994_04_29

When bubbles no longer come out, tighten the air bleed screw (1) and tighten the knob of the priming pump (2). Completely wipe off any spilt fuel. Start the engine and check for fuel leakage.

!

WARNING : Completely wipe off any spilt fuel after replacing a filter element or bleeding the system.

RELEASING PRESSURE IN THE HYDRAULIC SYSTEM IMPORTANT : Before carrying out any work on the hydraulic system, there should be no pressure in any of the circuits.

STEP 3

STEP 1 Place the machine on flat, level ground, lower the attachment to the ground and stop the engine.

STEP 2

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CS98M626

Lower the control cancellation lever, then unlock the machine controls, using the control unlocking switch on the left-hand control arm.

STEP 4

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CK98M014

Turn the starter switch key to the “ON” position.

CS98M629

Make sure the control locking indicator lamp goes out on the instrument console.

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A23875

CK98M014

Turn the starter switch key to “OFF” position.

Template Name: OM_1_col Template Date: 1994_04_29

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Operate the control levers from right to left and front to rear a dozen times approximately.

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STEP 6

STEP 5

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

Check the hydraulic reservoir fluid level.......................Every 10 hours or each day Draining water and sediment from the hydraulic reservoir ...................................................... Every 250 hours Replace the pilot filter ................................................................. Every 1000 hours Replace the drain filter ................................................................ Every 1000 hours Replace the reservoir breather element...................................... Every 1000 hours Clean the suction filter ................................................................ Every 1000 hours Replace the return filter............................................................... Every 1000 hours Replace the Ultra Clean filter ...................................................... Every 1000 hours Replace the suction filter............................................................. Every 5000 hours Change the hydraulic fluid .......................................................... Every 5000 hours Reservoir capacity ...................................................................................... 56 litres Total system capacity .................................................................................. 95 litres Type of oil......................................................................See “Fluids and lubricants”

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NOTA : If the machine is new or if a major part has been overhauled or replaced in the hydraulic system, replace the pilot filter, return filter and the drain filter after 50 hours of operation. After that, replace these filters at the normal interval of every 1000 hours.

!

WARNING : Hydraulic fluid or grease injected into your skin can cause severe injury or death. Keep your hands and body away from any pressurized leak. Use cardboard or paper to check for a leak. If fluid is injected into your skin, see a doctor immediately and have the fluid removed.

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Filling the reservoir

STEP 1

Place the machine on flat, level ground.

Stop the engine and remove the starter switch key.

CS98M570

STEP 2

CP99A009

Clean the cover plate and the area around the plate.

Remove the cover plate and add hydraulic fluid to the reservoir as required.

Replace the cover plate seal if required and install the cover plate.

CK98M023

The oil should be in the middle of the indicator. Add more oil if necessary. See “Filling the reservoir”.

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Place the machine on flat, level ground and place the attachment in the position shown. Stop the engine and remove the starter switch key.

Template Name: OM_1_col Template Date: 1994_04_29

Level in reservoir

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LUBRICATION/FILTERS/FLUIDS

LUBRICATION/FILTERS/FLUIDS

Template Name: OM_1_col Template Date: 1994_04_29

Draining water and sediment from the hydraulic reservoir

Pilot filter replacement

Place the machine on flat, level ground.

Stop the engine and remove the starter switch key.

Release all pressure in the hydraulic system. See “Releasing pressure in the hydraulic system”.

1 2 3 4 CK98M036

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CS98M617

Position a drain pan under the drain plug.

Loosen the drain plug on the bottom of the reservoir and drain the sediment and water accumulated at the bottom of the reservoir. After draining, tighten the drain plug.

CS98M619

Use a 24 mm wrench on the bottom of the filter body (4) and turn counterclockwise to remove.

Remove the old filter (3).

Clean the filter body (4) in solvent and wipe dry with a cloth.

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Coat the element seal and the new O-ring (2) with clean hydraulic fluid and install the filter (3) on the filter base (1).

Install the filter body (4) and tighten with a wrench. Do not overtighten.

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Place the machine on flat, level ground.

Stop the engine and remove the starter switch key.

Place the machine on flat, level ground.

Stop the engine and remove the starter switch key.

1

2

1 3 2 5

3

4

CS98M617

Clean the top of the hydraulic reservoir and clean the suction filter cover.

Remove the cover (1) and O-ring (2) and spring on the top of the suction filter rod assembly.

Remove the suction filter (3) and clean with solvent. Dry it completely and check it for any damage. If there is any damage on the surface, replace it with a new one.

Install a new O-ring (2) and install the suction filter (3), spring and rod assembly.

Remove the cover (1) and O-ring (2).

Take out spring (3), valve (4) and return filter (5).

Install a new filter. Clean the spring (3) and valve (4) and assemble them.

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CS98M617

Clean the top of the hydraulic reservoir and clean the return filter cover.

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Return filter replacement

Check O-ring (2) and replace it if worn or damaged.

Install the cover (1).

Install the cover (1).

NOTE : Install a new suction filter every 5000 hours of operation or when the hydraulic oil is replaced.

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Template Name: OM_1_col Template Date: 1994_04_29

Cleaning and replacement of the suction filter

LUBRICATION/FILTERS/FLUIDS

Template Name: OM_1_col Template Date: 1994_04_29

Ultra clean filter replacement

IMPORTANT : If the seals on the new element are not removed, the filter will not function correctly.

Place the machine on flat, level ground.

Stop the engine and remove the starter switch key.

Install the new filter element (6) in the filter body (5).

Install the spring (4), new O-ring (3) and cover (2).

Start the engine and run at idle speed.

Loosen the vent plug (7) on top of the cover. When air free hydraulic fluid comes out of the vent hole, tighten the vent plug (7). Clean all fluid from the filter body.

Reservoir breather replacement CK98M036

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1 7 2

1 3

2

4

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6

5

3

CI98M182

CS98M618

Clean the top of the filter with solvent.

Remove the four cover bolts (1) and remove the cover (2), O-ring (3) and spring (4).

Remove the screw (1), the cover (2) and the filter (3). Install a new filter (3) and then install the cover (2) and the screw (1).

Carefully lift the old filter element (6) out of the body (5).

Use a clean cloth and clean out the filter body (5).

Remove the four foil seals from the new filter element (6).

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Place the machine on flat, level ground.

Stop the engine and remove the starter switch key.

CK98M037

Put clean hydraulic fluid on the seal of the new drain filter.

Turn the new filter clockwise to install. Do not over-tighten.

CP99A009

Remove the reservoir cover plate.

Using a pump, remove the fluid from the hydraulic reservoir. Have a container with a suitable capacity ready.

CS98M617

Remove the drain plug to remove the remaining fluid from the reservoir.

Replace the suction filter, return filter, pilot filter, drain filter, Ultra Clean filter, and breather filter.

Install the reservoir drain plug.

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Turn the old filter counterclockwise to remove. Discard the old filter.

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Place the machine on flat, level ground.

Stop the engine and remove the starter switch key.

Replacing the hydraulic fluid

Template Name: OM_1_col Template Date: 1994_04_29

Drain filter

LUBRICATION/FILTERS/FLUIDS Put new hydraulic fluid into the reservoir.

See “Filling the reservoir”.

Template Name: OM_1_col Template Date: 1994_04_29

Install the reservoir cover plate.

IMPORTANT : Before you start the engine, it is very important that you bleed air from the hydraulic pump. Damage can occur to the pump if you do not follow these instructions.

Open the engine hood.

CK98M038

Loosen the bleed plug on the top of the swing reduction gear to release any air.

Tighten the air bleed plug when air free oil comes out of the plug hole.

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After the warm up procedure is completed, move each control slowly several times to remove any air in the system.

Swing the upperstructure evenly left to right two turns or more.

CS98M621

Clean the top of the pump and the air bleed plug with solvent and remove the air bleed plug on top of the pump.

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Fill the pump with new clean hydraulic fluid. Install and tighten the air bleed plug.

Stop the engine and wait five minutes.

Check the oil level in the hydraulic reservoir and add oil as required and check that there are no air bubbles in the hydraulic reservoir.

Start the engine and run at idle speed.

Loosen the air bleed plug on the pump.

Tighten the plug when air free fluid comes out of the bleed plug hole. Clean the area completely.

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Hydraulic fluid When using the hydraulic breaker, hydraulic fluid deteriorates more quickly than during ordinary digging. Check the hydraulic fluid level more frequently. In addition, when replacing the filters, also check the condition of the hydraulic fluid.

- Replace the hydraulic fluid and filter element using the graph below as a reference, depending on the operation frequency of the hydraulic breaker.

- If the hydraulic breaker work continues for 100 hours or more, replace the element every 100 hours.

- Replace the return filter for the hydraulic breaker at the same interval as the element.

4

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3

1

2

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Replacing the hydraulic fluid and filters when a hydraulic breaker is used (optional)

CS99A860

Template Name: OM_1_col Template Date: 1994_04_29

(1) Percentage of use (2) Intervals in hours (3) Hydraulic fluid replacement (4) Hydraulic filter replacement

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Return filter

Template Name: OM_1_col Template Date: 1994_04_29

Place the machine on flat, level ground.

Stop the engine and remove the starter switch key.

Remove the drain plug (6) and drain the hydraulic oil.

Remove the four screws (1) on top of the case and remove the cover (2), indicator and O-ring (3) assembly.

Replace the element (5) with a new one.

Discard the damaged O-ring.

Insert a new O-rings (3) and (4) and install the assembly.

Tighten the retaining screws (1) for the cover (2).

Install the drain plug (6).

Start the engine and run it at low speed.

Operate the hydraulic breaker and check that there are no leaks.

CK98M039

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7

1 2 3

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4 5

6 CS98M622

This filter is equipped with an indicator (7). When the red ring becomes visible, the filter must be changed.

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AIR FILTER

The hoses should be replaced before they are worn.

Service specifications Inspect and clean the primary element ......................................... Every 250 hours Replace the primary element ...................................................... Every 1000 hours or after cleaning six times Replace the secondary element.................................................. Every 1000 hours or after cleaning the primary element three times

IMPORTANT : Observe the air filter service intervals shown above. Clean filters mean longer engine life.

Removing the elements STEP 2

STEP 1

CP99B010

Remove the wing nut.

CP99B011

Remove the primary element.

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IMPORTANT : The primary element can be cleaned. The secondary element can not be cleaned and must be replaced.

Template Name: OM_1_col Template Date: 1994_04_29

Be sure to carry out regular checks on the air filter, intake manifold, seals and hoses.

At the same time, check the intake manifold screws and hose clamps for tightness.

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Inspection

LUBRICATION/FILTERS/FLUIDS

Cleaning the primary element

STEP 3

Template Name: OM_1_col Template Date: 1994_04_29

IMPORTANT : Make sure your face is protected before using compressed air.

CP99B012

Remove the wing nut.

STEP 4 PE08311

If the primary element is dry :

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Blow compressed air from the inside towards the outside at very low pressure.

The compressed air nozzle should be held at least 3 cm from the inside wall of the element. Cleaning is completed once no more dust comes out of the primary element.

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CP99B013

Remove the secondary element if it needs replacing.

IMPORTANT : The secondary element must be replaced, not cleaned.

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

PDE0378

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.

IMPORTANT : Allow the primary element to dry completely before installing. It is advisable to keep a spare, clean the primary element ready for installation while the other primary element is drying.

IMPORTANT : Replace the primary element if light can be seen through a hole, however small.

Installing the elements STEP 1

CP99B012

Install the secondary element and tighten the wing nut.

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Check the primary element for damage by placing an inspection lamp inside the element.

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Inspecting the primary element

Template Name: OM_1_col Template Date: 1994_04_29

IMPORTANT : Compressed air pressure should not exceed 7 bar.

LUBRICATION/FILTERS/FLUIDS STEP 3

STEP 2

Template Name: OM_1_col Template Date: 1994_04_29

CP99B010

CP99B010

Install the primary element and tighten the wing nut.

Check that the dust ejector under the filter is working correctly.

IMPORTANT : If exhaust smoke is abnormal after cleaning, the air filter primary element must be replaced.

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Template Name: OM_1_col Template Date: 1994_04_29

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The upper and lower rollers and idler wheels use a permanent floating seal type sealing mechanism. The service life normally lasts until overhaul, but check visually everyday before work for oil leakage. If oil leakage is found, component replacement is necessary. See your CASE Dealer.

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TRACK ROLLERS AND IDLER WHEELS

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LUBRICATION/FILTERS/FLUIDS

TRAVEL REDUCTION GEARS Service specifications Template Name: OM_1_col Template Date: 1994_04_29

Oil level check ............................................................................... Every 250 hours Oil change ................................................................................... Every 1000 hours (after the first 250 hours of operation) Oil capacity (per reduction gear) ................................................................ 1.7 litres Oil type ..........................................................................See “Fluids and lubricants”

Level STEP 1

STEP 4

Park the machine on flat, horizontal ground.

3

STEP 2

2 TRIM THIS EDGE

CP99A008

1

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Move the machine so that plug (1) is in the lowest possible position.

Remove plug (2) and check the oil level.

The oil must be level with the bottom edge of the orifice (2). If necessary, remove plug (3) and add oil through orifice (3) until the level comes up to the bottom edge of orifice (2).

STEP 3

STEP 5

Stop the engine and remove the starter switch key.

Install plugs (2) and (3).

CP99A008

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

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STEP 5

STEP 1

Allow the oil to drain.

Park the machine on flat, horizontal ground.

STEP 6

3

STEP 2

2 1 1

CP99A008

Move the machine so that plug (1) is in the lowest possible position.

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

STEP 7 Repeat Steps 2 to 6 for the other travel reduction gear.

STEP 4

CP99A008

Place a receptacle of a suitable capacity under the travel reduction gear and remove the three plugs.

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CP99A008

Install plug (1), fill with oil through orifice (3) until the level comes up to the bottom edge of orifice (2), then install plugs (2) and (3).

Template Name: OM_1_col Template Date: 1994_04_29

Draining and refilling

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LUBRICATION/FILTERS/FLUIDS

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MAINTENANCE/ADJUSTMENTS

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

Clean.................................................When the machine has been working in mud Check tension ............................................................................... Every 100 hours Check steel pad screw torques ..................................................... Every 250 hours (after the first 50 hours during the run-in period) Inspect rubber tracks (optional) ..................................Every 10 hours or every day IMPORTANT : If tracks are too tight, they wear quickly.

If tracks are not tight enough, they wear quickly and the links can catch on the sprocket wheel or slide off the idler wheel or the sprocket wheel. Clean the tracks after work. For rubber tracks avoid turning the machine on the spot, since this can cause rapid wear of the tracks and jamming with stones, rocks, etc. Avoid working in areas with beds of loose stones or rubble, pieces of reinforced concrete or grooved steel plates.

Cleaning TRIM THIS EDGE

When the machine has been working in mud, a reduction in temperature can cause the mud to solidify.

STEP 2

STEP 1

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CK98M016

Turn the engine throttle button to maximum speed position.

CS98M557

Place the upperstructure at right angles to the undercarriage. Use the attachment to press on the ground and lower the boom until the track is raised off the ground.

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MAINTENANCE/ADJUSTMENTS

Checking tension

STEP 3

Park the machine on flat, horizontal ground.

STEP 2 Clean the tracks.

STEP 3

CK98M012

Use the travel speed selection pedal to select high speed.

CS98M557

Place the upperstructure at right angles to the undercarriage. Use the attachment to press on the ground and lower the boom until the track is raised off the ground.

STEP 4 Use the travel control lever to operate the track in reverse for a few moments.

STEP 5

Repeat Steps 1 to 4 for the other track.

Stop the engine and remove the starter switch key.

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Template Name: OM_1_col Template Date: 1994_04_29

CK98M012

Operate the travel control lever for the raised track forwards and then in reverse, to remove the mud.

STEP 5

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STEP 4

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STEP 1

MAINTENANCE/ADJUSTMENTS

Adjusting tension

STEP 6

Template Name: OM_1_col Template Date: 1994_04_29

This operation is to be carried out after the tension has been checked.

To increase tension STEP 1

PE07531

Measure the sag of the track at the center between the base of the undercarriage and the pad.

The value should be between 180 mm and 205 mm.

CP99B021

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STEP 7

Clean the grease fitting adaptor and connect the grease pump hose to the grease fitting.

Adjust tension if necessary.

STEP 8 Repeat Steps 3 to 7 for the other track.

STEP 2

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PE07531

Inject grease to obtain the right amount of track sag.

The value should be between 180 mm and 205 mm.

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MAINTENANCE/ADJUSTMENTS

Remove the grease gun and clean the grease fitting.

STEP 4 Repeat Steps 1 to 3 for the other track.

To reduce tension STEP 1

PE07531

As soon as the right track sag is obtained, tighten the adaptor.

The value should be between 180 mm and 205 mm.

Clean the grease adaptor and fitting.

STEP 4

CP99B022

Loosen the grease fitting adaptor about three turns to allow grease to flow out of the cylinder.

IMPORTANT : If the grease fitting adaptor is damaged, grease may leak out. Check the condition of the grease fitting adaptor regularly and replace it if necessary.

Template Name: OM_1_col Template Date: 1994_04_29

!

WARNING : Never unscrew the grease fitting adaptor completely to speed up the flow of grease. The grease in the cylinder is under high pressure.

Repeat Steps 1 to 3 for the other track.

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STEP 3

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STEP 2

STEP 3

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MAINTENANCE/ADJUSTMENTS

Steel pad screw torque

Replacing rubber tracks (optional)

Template Name: OM_1_col Template Date: 1994_04_29

Removal STEP 1 Slacken the track tension off completely.

See “Adjusting the tension”.

STEP 2

PE08316

Tighten the pad screws to a torque between 196 and 235 Nm.

Checking the condition of rubber tracks (optional) TRIM THIS EDGE

CS98M557

3

Place the upperstructure at right angles to the undercarriage. Use the attachment to press on the ground and lower the boom until the track is raised off the ground.

2

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STEP 3

A

Stop the engine and remove the starter switch key.

1 CS98A190

The tracks should be replaced if any of the following cases occurs : - The lugs (1) are worn, A = minimum 5 mm.

- The steel layer (2) is visible or broken.

- The metal reinforcements (3) are visible or worn.

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MAINTENANCE/ADJUSTMENTS

CS98B246

STEP 8 Repeat Steps 1 to 7 for the other track.

WARNING : Make sure that the tension cylinder is completely slackened off before all other operations.

Installation TRIM THIS EDGE

!

Remove the track.

STEP 1

STEP 5

CS98B246

Place the track on the sprocket wheel and on the side member.

CS98B209

Operate the travel lever of the track concerned in reverse. Stop the movement when the tubes are pressing against the idler wheel.

STEP 6 Stop the engine and remove the starter switch key.

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Template Name: OM_1_col Template Date: 1994_04_29

CS98B208

Place tubes in the track slots in front of the idler wheel.

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STEP 7

STEP 4

MAINTENANCE/ADJUSTMENTS STEP 2

STEP 5

Template Name: OM_1_col Template Date: 1994_04_29

CS98B247

CS98B209

Place tubes in the slots in the track in front of the idler wheel.

Position the track on the idler wheel.

STEP 6

STEP 3

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CS98B249 CS98B248

Operate the travel lever of the track concerned in reverse. Stop the movement when the tubes are pressing against the idler wheel.

Operate the travel lever for the track concerned to disengage the tubes from the track.

STEP 7

STEP 4

Adjust the tension. See “Adjusting the tension”.

Stop the engine and remove the starter switch key.

STEP 8 Repeat Steps 1 to 7 for the other track.

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MAINTENANCE/ADJUSTMENTS

RADIATOR AND OIL COOLER Check for leakage ...................................................... Every 10 hours or every day Clean ............................................................................................. Every 500 hours

Cleaning

IMPORTANT : Make sure your face is protected before using compressed air.

IMPORTANT : The use of trichlorethylene is strictly forbidden.

2

CK98M021

Template Name: OM_1_col Template Date: 1994_04_29

Remove the wing nuts (1) and then remove the grille (2).

Clean the radiator and the oil cooler: - Dry dust : use compressed air.

- Mud : clean with a hose.

- Greasy deposits : use perchlorethylene.

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Install the grille (2) and the wing nuts (1).

1

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Service specifications

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MAINTENANCE/ADJUSTMENTS

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

Visual check ................................................................Every 10 hours or every day Check belt tension ........................................................................ Every 250 hours

Tension check

Tension adjustment

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CS98M560

CS98M572

Press the center of the belt, exerting a pressure of about 10 kg. The belt deflection should be about 8 to 12 mm.

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NOTE : Check if there are any signs of wear damage to the pulleys or the belt.

Check carefully to ensure that the belt is correctly positioned in the pulley grooves.

If the belt is stretched, cracked or frayed, it must be replaced.

Loosen the two mounting bolts. Use a lever to move the alternator outwards until belt tension is correct. Tighten the alternator mounting bolts.

IMPORTANT : If the engine runs with the belt slack, the belt can slip in its housing and cause the engine to overheat or the battery to receive insufficient charge.

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MAINTENANCE/ADJUSTMENTS

CS98M628

CS98M572

If the drive belt breaks, the battery charge warning lamp lights up on the instrument console.

Remove the two mounting bolts. Use a lever to push the alternator inwards.

Remove the warn belt.

Adjust the belt tension.

Tighten the two mounting bolts.

Template Name: OM_1_col Template Date: 1994_04_29

Start the engine and make sure the warning lamp on the instrument console does not come on.

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Install a new belt.

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Replacing the drive belt

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MAINTENANCE/ADJUSTMENTS

FUEL TANK FILTER Service specification Template Name: OM_1_col Template Date: 1994_04_29

Clean filter ....................................................................................... Every 50 hours Remove the filter and clean it in diesel oil.

NOTE : To refill the fuel tank, see “Fluids and lubricants” in the “Lubrication/Filters/ Fluids” Section.

CP99B014

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ADJUSTING ENGINE ROCKER ARM CLEARANCE Service specification Check .......................................................................................... Every 1000 hours NOTE : Have your CASE Dealer check the clearance.

INSPECTING AND CLEANING THE MACHINE

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Service specifications Inspect and clean ........................................................................ Every 1000 hours Or whenever oil or grease has been spilt on the machine. Clean off with steam or a high pressure water jet.

Take the opportunity during this operation to make a visual check of all the welded components (in case of appearance of cracks), the attachment linkages and check the teeth and tooth tips for correct retention and for wear. Look for any leaks and check the condition of all pipes and hoses.

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MAINTENANCE/ADJUSTMENTS

1.

Wipe clean the rod and bearing on the cylinder to be cleaned.

2.

Operate normally for five or ten minutes.

3.

Extend the cylinder rod.

4.

Carry out the leak test.

ROD APPEARANCE

TEST

CONCLUSION

Dry

Slight traces of oil when a piece of paper is wiped over 20 cm of the rod.

Normal

Slightly oily

Paper remains stuck to rod when run over rod.

Normal

Oily

Paper remains stuck when placed on rod.

Normal

Very oily or weeping

Each time cylinder rod is extended, a ring of oil can be seen on the rod.

Leakage

Each time the rod retracts, the excess oil drips from the gland.

Consult your CASE Dealer

PLASTIC AND RESIN PARTS

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A cylinder rod should be slightly oily. Check that there are no leaks after a period of work, when the whole hydraulic system is at normal operating temperature.

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CHECKING FOR CYLINDER LEAKAGE

The use of gasoline, paraffin, paint solvents, etc. will cause discoloration, cracks or deformation of these parts.

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Template Name: OM_1_col Template Date: 1994_04_29

When cleaning plastic screens, for example on the instrument console or the control arms, do not use gasoline, kerosene, paint solvents, etc... Use soap and water and a clean cloth only.

MAINTENANCE/ADJUSTMENTS

REPLACING A TOOTH TIP ON A BACKHOE BUCKET Removal Template Name: OM_1_col Template Date: 1994_04_29

STEP 3

STEP 1

CP99B015

CP99B017

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Place the bucket a few centimetres above the ground. Stop the engine and remove the starter switch key.

Remove the worn tooth tip.

STEP 2

STEP 1

Installation

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CP99B017

CP99B016

Remove the locking pin from its housing by striking it with a hammer until it is ejected.

Clean the mating surface on the adaptor.

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MAINTENANCE/ADJUSTMENTS

CP99B017

CP99B018

Install a new tooth tip up to the stop and hold it in this position.

Place the locking pin in position and strike it until it is flush with the tooth tip.

Template Name: OM_1_col Template Date: 1994_04_29

NOTE : When replacing a tooth tip, it is advisable to replace the locking pin at the same time.

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IMPORTANT : Make sure the locking pin is not installed back to front.

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STEP 3

STEP 2

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MAINTENANCE/ADJUSTMENTS

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

Removal

Installation

STEP 1

STEP 1

Place the bucket flat on flat, horizontal ground. Operate the attachment controls so that the dipper/bucket linkage pin is not gripped by the weight of the dipper.

Install the linkage seals on the bucket bushing shoulders. Change them if necessary.

STEP 2

STEP 2

Stop the engine and remove the starter switch key.

Start the engine. Move the dipper into its housing. Stop the engine and remove the starter switch key.

STEP 3

STEP 3

TRIM THIS EDGE CP99B019

CP99B019

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Remove the retaining rings and pins and then remove the bucket linkage pins.

Install the dipper/bucket linkage pin and the retaining pins and rings.

STEP 4

STEP 4

Start the engine.

Start the engine. Extend the bucket cylinder rod to bring it into its housing. Stop the engine and remove the starter switch key.

STEP 5 Disengage the attachment from the bucket and retain the linkage seals for reuse.

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MAINTENANCE/ADJUSTMENTS STEP 6

STEP 5

STEP 7 Grease the linkages.

CP99B019

Install the connecting rod/bucket linkage pin and the retaining pins and rings.

Whenever carrying out a welding operation on the undercarriage or upperstructure carriage as authorized by the manufacturer and in accordance with his instructions, disconnect the batteries, disconnect the alternator B+ and D+ terminal wires and connect the welding apparatus earth cable to the component on which the welding operation is to be performed. Never connect the welding apparatus to the undercarriage when welding on the upperstructure (or vice-versa). Never connect the welding apparatus earth to a component of the hydraulic system.

Template Name: OM_1_col Template Date: 1994_04_29

!

WARNING : Any unauthorized modifications made to this machine can cause serious injury. Do not undertake any modifications without first consulting your CASE Dealer.

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WELDING ON THE MACHINE

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Push the seals back into their housings.

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MAINTENANCE/ADJUSTMENTS

REPLACING A TOOL ON A HYDRAULIC BREAKER (optional) Template Name: OM_1_col Template Date: 1994_04_29

Removal Tools required

STEP 4

- A hammer - A bronze or brass drift - A flat-headed screwdriver STEP 1

CP99C007

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Drive out the mounting pins with a bronze or brass drift.

STEP 5 CP99C005

lace the hydraulic breaker laying on hard, flat ground.

STEP 2

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p the engine and remove the starter switch key.

STEP 3

CP99C008

Remove the tool. Use a lifting device if necessary.

NOTE : If the hydraulic breaker is still on the machine, it may be easier to stick the tool in the ground and lift the hydraulic breaker off the tool. Make sure that the tool can not fall.

CP99C006

Push the rubber plate upwards (if fitted).

Remove the retaining pins and plugs from both sides of the hydraulic breaker.

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Installation

STEP 4

Tools required

Install the mounting pins and make sure the tool is secure.

- A hammer - A bronze or brass drift - A flat-headed screwdriver

STEP 5

STEP 1

CP99C009

Check the tool bushing and oil seal for wear and replace them if necessary.

See “Replacing a tool bushing on a hydraulic breaker”.

STEP 2

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CP99C011

Install the plugs and retaining pins. Put the rubber plate (if fitted) back at the bottom.

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MAINTENANCE/ADJUSTMENTS

Clean and coat the tool and mounting pins with grease.

CP99C010

Insert the tool, aligning the grooves on the tool with the mounting pin holes.

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Template Name: OM_1_col Template Date: 1994_04_29

STEP 3

MAINTENANCE/ADJUSTMENTS

REPLACING A TOOL BUSHING ON A HYDRAULIC BREAKER (optional) Template Name: OM_1_col Template Date: 1994_04_29

Removal

Installation

Tools required

Tools required

- A hammer - A bronze or brass drift

- A hammer - A bronze or brass drift

STEP 1

STEP 1

Remove the tool. See “Replacing a tool on a hydraulic breaker”.

STEP 2

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CP99C014

Check the condition of the oil seals and replace them if necessary.

CP99C012

Drive out the mounting pins and plugs.

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STEP 3

STEP 2 Lubricate the contact surfaces of the tool bushing and its housing.

CP99C013

Remove the tool bushing.

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MAINTENANCE/ADJUSTMENTS

CP99C013

Install the tool bushing in its housing and then install the mounting pins and plugs.

STEP 4

Template Name: OM_1_col Template Date: 1994_04_29

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Install the tool. See “Replacing a tool on a hydraulic breaker”.

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STEP 3

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MAINTENANCE/ADJUSTMENTS

REPLACING A HYDRAULIC BREAKER (optional) Template Name: OM_1_col Template Date: 1994_04_29

Removal

STEP 4

STEP 1

Remove the retaining hardware (this can vary depending on the mounting arrangement).

STEP 5 Remove the connecting rod/hydraulic breaker linkage pin and the dipper/ hydraulic breaker linkage pin.

STEP 6 Operate the machine controls to free the hydraulic breaker.

CP99C005

Place the hydraulic breaker laying on hard, flat ground.

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STEP 2 Stop the engine and remove the starter switch key. Release all pressure in the hydraulic system. See “Releasing pressure in the hydraulic system” in the “Lubrication/Filters/Fluids” Section.

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STEP 3

Installation STEP 1 Use the attachment controls to engage the dipper in the hydraulic breaker.

STEP 2 Stop the engine and remove the starter switch key. Release all pressure in the hydraulic system. See “Releasing pressure in the hydraulic system” in the “Lubrication/Filters/Fluids” Section.

STEP 3 Install the dipper/hydraulic breaker linkage pin. Place a receptacle of a suitable capacity under the hydraulic lines. Connect the hoses to the hydraulic breaker.

CP99C005

Place a receptacle of suitable capacity under the hydraulic lines. Close the shutoff valves (for opening or closing the circuit) on the lines, if fitted. Disconnect the hoses from the tubes. Plug if necessary.

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MAINTENANCE/ADJUSTMENTS

Operate the connecting rod control so as to engage it in the hydraulic breaker, then stop the engine and remove the starter switch key.

STEP 5 Install the connecting rod/hydraulic breaker linkage pin and then install the retaining hardware (this can vary depending on the mounting arrangement) on the linkage pins.

STEP 6 Open the shut-off valves (for opening or closing the circuit) on the lines, if fitted.

STEP 7

Template Name: OM_1_col Template Date: 1994_04_29

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Grease the linkage pins.

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STEP 4

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MAINTENANCE/ADJUSTMENTS

WEAR LIMITS ON A HYDRAULIC BREAKER (optional) Tool bushing Template Name: OM_1_col Template Date: 1994_04_29

The maximum acceptable wear limit is : 72 mm For replacement, see “Replacing a tool bushing on a hydraulic breaker”.

CS99C628

Tool New

Wear limit

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Ø 70 mm .................................Ø 68 mm For replacement, see “Replacing a tool on a hydraulic breaker”.

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CS99C630

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MAINTENANCE/ADJUSTMENTS

Recommended weekly checks Check the assembly hook for wear on the contact face with the pin which can increase the pin passage dimension (maximum wear 2 mm). If wear is considerable, consult your CASE Dealer.

Check that the safety shaft is not damaged and that it is securely in place. Replace it if necessary.

Incorrect quick coupler operation IMPORTANT : Make sure that the attachment is fully lowered to the ground, stop the engine and remove the starter switch key before carrying out any of the following checks.

- Check that no pin is broken, bent or lost.

- Check that the cylinder is not damaged or bent.

- Check that there is no leak, etc. at any hydraulic hose.

After carrying out these checks, consult your CASE Dealer.

!

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

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If the quick coupler does not operate correctly, check the following :

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INSPECTING AND SERVICING THE QUICK COUPLER (optional)

IMPORTANT : If your quick coupler is used in particularly harsh conditions (dusty or corrosive environment, etc...) reduce the service intervals accordingly.

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Template Name: OM_1_col Template Date: 1994_04_29

Any modification of the quick coupler without prior authorization can cause serious injury. Do not undertake any modifications without authorization from your CASE Dealer.

MAINTENANCE/ADJUSTMENTS

FIRE EXTINGUISHER (not supplied) Template Name: OM_1_col Template Date: 1994_04_29

CS98M573

CP99B020

It is strongly recommended to have a fire extinguisher available and to keep it in the right-hand side hood.

Service specifications TRIM THIS EDGE

Every month : Inspect the extinguisher and check it is not damaged.

Every six months : Have the chemical removed and have the fire extinguisher refilled by an approved organization.

Every year : Have the fire extinguisher inspected by an approved organization.

AIR CONDITIONING (optional) Service specification

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Have checked by a specialist......................................................... Every 6 months The components of the air conditioning system need servicing at regular intervals.

Make sure these intervals are respected, in order to ensure the air conditioning functions correctly and with maximum effectiveness. The air conditioning system contains gas which is subject to strict legislation. Any defect in the system must be fixed rapidly.

!

WARNING : Never try to service the air conditioning system yourself. For any service work, consult your CASE Dealer.

NOTE : Operate the air conditioning system at least once a week, if only for a short time. See “Air conditioning”, in the “Controls/Instruments/Accessories” Section.

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MAINTENANCE/ADJUSTMENTS

SOLUTION Check switch

Defective rotation of starter (starter rotates slowly)

Discharged batteries, starter problems, contaminated or loose wiring connectors

Incorrect viscosity of engine oil

Inspect and replace as necessary

Incomplete air bleeding of fuel system

Completely bleed air

Engine too cold (cold weather)

Preheat the intake air or warm up the coolant

No fuel in fuel tank

Refill

Poor fuel quality

Inspect and replace as necessary

Fuel filter clogged

Clean or replace

Possible seizure in engine Low compression

See your CASE Dealer

Defective fuel injection pump

Engine stops during operation.

No fuel in fuel tank

Refill

Fuel filter clogged

Clean or replace

Air in the fuel system

Retighten fuel in line connections

Low oil

Refill

Oil filter clogged

Replace oil filter

Low oil viscosity

Replace with oil of viscosity to match temperature

Oil leakage from connections

Tighten connections

Improper oil pressure.

Defective oil pressure switch Incorrect functioning of oil pump

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See your CASE Dealer

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Engine does not start.

POSSIBLE CAUSE Defective starter switch (starter does not run)

Template Name: OM_1_col Template Date: 1994_04_29

PROBLEM

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ENGINE TROUBLESHOOTING

MAINTENANCE/ADJUSTMENTS Engine troubleshooting (continued) PROBLEM

Template Name: OM_1_col Template Date: 1994_04_29

Exhaust from engine is white or blue.

POSSIBLE CAUSE

SOLUTION

Excessive oil

Disassemble and repair, replace parts

Excessively low oil viscosity

Replace with correct oil viscosity

Excessive cooling by radiator

Adjust

Incorrect fuel injection timing Low compression

Exhaust from engine is black or dark gray.

See your CASE Dealer

Improper fuel

Replace with correct fuel

Incorrect valve clearance

Adjust

Insufficient air intake (air cleaner clogged)

Service the air filter

Defective fuel injection pump Low compression

See your CASE Dealer

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Incorrect fuel

Replace with correct fuel

Insufficient air intake

Clean or replace element

Defective fuel injection pump Excessive fuel consumption.

Incorrect spray from fuel injection nozzle

See your CASE Dealer

Incorrect fuel injection timing Low compression

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Excessive oil

Drain oil to proper level

Low oil viscosity

Replace with oil of viscosity to match temperature

Oil leakage

Retighten and replace parts if necessary

Worn cylinder piston ring

See your CASE Dealer

Poor fuel quality

Replace

Damage inside muffler

Replace

Excessive engine oil consumption.

Unusual noise (fuel or mechanical).

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MAINTENANCE/ADJUSTMENTS Engine troubleshooting (continued)

Engine overheating (water temperature is too high).

POSSIBLE CAUSE

SOLUTION

Low coolant

Refill

Water leakage

Repair

Worn or damaged belt

Replace

Incorrect mixture of anti-freeze solution

Replace

Defective radiator Broken fan Defective thermostat

See your CASE Dealer

Defective water pump Defective water temperature gauge Adjust Repair

Defective battery

Replace

Defective regulator

See your CASE Dealer

Template Name: OM_1_col Template Date: 1994_04_29

Defective alternator

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Defective battery charge.

Incorrect belt tension Electrical wiring problems

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PROBLEM

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197

ELECTRICAL SYSTEM

FUSES Template Name: OM_1_col Template Date: 1994_04_29

IMPORTANT : Before proceeding to replace a fuse, turn the starter switch key to “OFF”.

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

CK98M018

CK98M017

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The fuses are located under the righthand control arm.

A notice on the cover gives the function and amperage of each fuse.

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12

3

13

4

14

5

15

6

16

7

17

8

18 19

9 10

20 CS98M567

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20)

Left-hand and right-hand control arms, air conditioning, 24V - 12V convertor................................................................................. 10 A Starter switch ........................................................................................... 10 A Air conditioning, heater............................................................................ 20 A Attachment, upperstructure frame and cab working lights ...................... 20 A Condenser ventilator motor ..................................................................... 15 A Not used .................................................................................................. 15 A Not used .................................................................................................. 15 A Windshield wiper/washer ......................................................................... 10 A Horn, operator’s compartment light ......................................................... 10 A Cigarette lighter ....................................................................................... 10 A Throttle motor control unit........................................................................ 15 A Pre-heating control, left-hand control arm, swing lock, high speed travel mode, horn .................................................................. 10 A Engine shut-down solenoid valve ............................................................ 20 A Control cancellation ................................................................................. 10 A 24V - 12V convertor................................................................................. 10 A Rotating beacon ...................................................................................... 10 A Fuel filler pump, overload indicator.......................................................... 20 A Option solenoid valve .............................................................................. 15 A Not used .................................................................................................. 10 A Not used .................................................................................................. 10 A 193

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Template Name: OM_1_col Template Date: 1994_04_29

2

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11

1

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ELECTRICAL SYSTEM

ELECTRICAL SYSTEM

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

Check electrolyte level .................................................................. Every 250 hours or whenever the warning lamp on the instrument console comes on NOTE : When starting the machine with booster batteries, see “Connecting booster batteries”.

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!

WARNING : Before carrying out any service work on electrical system components, turn the starter switch key to the “OFF” position. When disconnecting batteries, always disconnect the negative (-) cable first. When reconnecting batteries, always connect the negative (-) cable last.

!

WARNING : Batteries give off explosive gases. Keep all naked flames, sparks and cigarettes away. Ensure adequate ventilation when charging batteries or when using in a confined place. Always protect your eyes when working near batteries.

Warning lamp

Access to batteries

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CS98M628

CK98M022

If the warning lamp lights up on the instrument console, then it is necessary to check the battery electrolyte level, even if a regular service inspection is not due.

Open the engine hood and remove the protection plate.

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ELECTRICAL SYSTEM

Make sure the warning lamp on the console does not come on.

!

WARNING : The electrolyte in the batteries can cause serious burns. Batteries contain sulphuric acid. Avoid contact with skin, eyes and clothing.

Antidote : EXTERNAL : rinse with water.

INTERNAL : drink large amounts 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 immediately.

!

WARNING : A spark or a naked light can cause the hydrogen in a battery to explode. To prevent explosion, proceed as follows : - 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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A24643

Remove the cell caps and check the level in each battery cell. The level should be between 10 and 15 mm above the plates.

Add distilled water if necessary, then install the cell caps.

NOTE : Make sure the battery terminals are clean and coated with grease and that the cables are properly tightened.

Template Name: OM_1_col Template Date: 1994_04_29

IMPORTANT : When adding distilled water at temperatures below 0 °C, the batteries must be charged or the engine run for two hours approximately in order to ensure that the distilled water and the electrolyte are properly mixed.

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Checking the electrolyte level

ELECTRICAL SYSTEM

CONNECTING BOOSTER BATTERIES Template Name: OM_1_col Template Date: 1994_04_29

!

WARNING : Connecting auxiliary cables wrongly or short-circuiting batteries terminals can cause an accident. Connect auxiliary starting cables as per the following instructions.

Make sure that the voltage of the booster batteries is the same as that of the machine system (24 volts).

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1.

Remove the protective plate.

2.

Remove the terminal covers.

3.

Connect the positive (+) cable to the positive (+) terminal on the first machine battery.

4.

Connect the negative (-) cable to the negative (-) terminal on the second machine battery.

5.

Start the engine.

6.

Remove the booster battery negative (-) cable and then the positive (+) cable.

7.

Install the terminal covers.

8.

Install the protective plate.

ALTERNATOR Service specification

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Check .......................................................................................... Every 1000 hours

!

WARNING : Whenever carrying out a welding operation on the machine, as authorized by the manufacturer and in accordance with his instructions, or making repairs to the electrical system, disconnect the alternator B+ and D+ wires. Be sure to identify the wires correctly when reconnecting.

IMPORTANT : Do not use a steam cleaning apparatus or cleaning solvent to clean the alternator.

Have the alternator checked by your CASE Dealer.

NOTE : Make sure the tag covers are correctly in place.

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ELECTRICAL SYSTEM

STARTER MOTOR Check .......................................................................................... Every 1000 hours Have the starter motor checked by your CASE Dealer.

Template Name: OM_1_col Template Date: 1994_04_29

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NOTE : Make sure the tag covers are correctly in place.

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Service specification

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199

STORAGE

STORING THE MACHINE Preparation for storage Template Name: OM_1_col Template Date: 1994_04_29

The following procedure applies when the machine is to be stored for a month or more.

Store the machine on flat, level ground, inside a building or, if not possible, outside and covered with a tarpaulin. Before storing the machine, carry out the following operations : 1.

Clean the machine.

2.

Retract the dipper cylinder rod as for as possible and lower the boom until the attachment is resting on the ground.

3.

Grease the machine thoroughly. The exposed surfaces of the cylinder rods should be greased or covered with a protective film. See your CASE Dealer.

NOTE : When the machine resumes service, the film will disappear automatically.

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4.

Drain the fuel tank and fill with a mixture of 90% diesel fuel and 10% anti-corrosive oil. Run the engine at idle speed for five minutes to allow the anti-corrosive oil to reach the lines, filters, pump and injectors.

5.

While the engine is still warm, drain the oil sump, fill with anti-corrosive oil and replace the engine oil filter.

6.

When the engine is cold, clean the outer parts of the engine with diesel fuel.

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7.

Clean or replace the air filter element.

8.

Drain the cooling system, leave the drain valves open and do not tighten the radiator cap.

9.

Remove the batteries, clean the battery housings and make sure not to leave any traces of acid. Store the batteries in a cool, dry place, where temperature is always above freezing.

10. Paint any areas where the paintwork is not good.

11. Plug the air filter inlet and the exhaust pipe.

12. Remove the starter switch key and place a “Do not operate” label on the righthand control arm and then raise the control cancellation lever.

13. Lock the hoods and the cab door.

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STORAGE

Periodic checks 1.

The electrolyte level in the batteries and the battery charge. Recharge the batteries if necessary.

2.

The grease on the cylinder rods.

3.

The fuel level in the fuel tank and the corrosive oil level in the engine. Add more if necessary.

4.

The condition of all lines, connectors and clamps (rust). Grease if necessary.

5.

The condition of the paintwork. Apply a coat of anti-rust treatment where necessary.

1.

Close the drain valves and fill the cooling system.

2.

Drain the fuel tank and fill with clean diesel fuel.

3.

Drain the engine sump, fill with clean engine oil and check the oil level.

4.

Change the fuel filter.

5.

Install the batteries.

6.

Grease the machine thoroughly.

7.

Check the condition of the fan drive belt and replace it if necessary.

8.

Check the hydraulic fluid level and add more fluid if necessary.

9.

Check the travel reduction gears oil level and add more oil if necessary.

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Starting up after storage

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Every month, check :

10. Clean the cylinder rods.

11. Unplug the air filter inlet and the exhaust pipe.

13. Keep a careful watch on all instrument console lamps and indicators.

!

WARNING : Check the machine for leaks or for any other parts that are broken, defective or missing.

!

WARNING : Before starting the engine, make sure that all controls are in neutral position. This prevents the machine from moving unexpectedly or an electrical appliance from starting up.

!

WARNING : Avoid running the engine in a confined place. Make sure there is adequate ventilation at all times.

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Template Name: OM_1_col Template Date: 1994_04_29

12. Remove the “Do not operate” tag and start the engine, following the starting up procedure.

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SPECIFICATIONS

ENGINE Template Name: OM_1_col Template Date: 1994_04_29

Make and type .................................................................................ISUZU A-4JB1 Number of cylinders .............................................................................................. 4 Bore/stroke...................................................................................93 mm x 102 mm Displacement ........................................................................................... 2771 cm3 Cooling ....................................................................................................... by water Batteries start .............................................................................. 2 12 volt batteries

Working conditions Speed....................................................................................................... 2100 rpm Power : ECC 1289 ................................................................. 40.5 kW (55 ch) Capacity : Engine oil................................................................................... 6.8 L Fuel tank................................................................................... 140 L

HYDRAULIC SYSTEM TRIM THIS EDGE

Two variable displacement, axial piston type pumps for supplying attachments, swing and travel motors.

Main pump output ..............................................................................2 x 75.6 L/mn One pump for supplying the dozer blade Maximum dozer blade pump displacement............................................. 25.5 L/mn

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Safety valve pressure setting Attachment.............................................................................................. 304 bar Swing ...................................................................................................... 206 bar Travel ...................................................................................................... 284 bar Dozer blade ............................................................................................ 225 bar

Control valves Five control valve sections for left-hand travel, boom, dipper, option circuit and swing.

Four control valve sections for right-hand travel, boom, dipper and bucket.

One control valve section for the dozer blade.

Load holding valve on boom and dipper.

Swing Fixed flow, piston-type pump.

Disk brake.

Upperstructure swing speed ..................................................................... 13.5 rpm

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SPECIFICATIONS

Variable displacement, axial piston type hydraulic motors.

Planetary reduction gears.

Low speed .............................................................................................0 to 3.7 kph High speed ...............................................................................................0 to 5 kph Gradeability ................................................................ 70% (45% with dozer blade) Tractive effort ...............................(slow speed) 5800 daN, (high speed) 3900 daN Crowd force (with 1.74 m dipper) .............................................................5540 daN Break-out force (with 1.74 m dipper) ........................................................3900 daN Hydraulic reservoir capacity ............................................................................. 56 L Total hydraulic system capacity........................................................................ 95 L

One-piece frame with welded components.

Lubricated track rollers and idler wheels.

Grease cylinder track tension system.

Steel tracks ........................................................................... 450 mm and 600 mm Rubber tracks ............................................................................................. 450 mm Ground pressure (with 450 mm pads)........................................................ 0.34 bar Chain guide .................................................................................................. in front

SAFETY DEVICES Controls locked by raising control cancellation lever.

Horn.

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UNDERCARRIAGE

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Translation

INDICATORS AND GAUGES Engine coolant solution temperature, fuel level and hourmeter.

Engine oil pressure, coolant temperature and hydraulic fluid temperature, battery charge, battery electrolyte level, fuel level, upperstructure frame swing lock, control lock, travel speed and pre-heating.

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Template Name: OM_1_col Template Date: 1994_04_29

WARNING AND INDICATOR LAMPS

SPECIFICATIONS

NOISE LEVELS Template Name: OM_1_col Template Date: 1994_04_29

Guaranteed by the manufacturer.

In accordance with European directive 86/662/EEC (as modified).

Inside the operator’s compartment (LpA).............................................. 80 decibels Outside the operator’s compartment (LwA) .......................................... 99 decibels

WEIGHTS With monobloc boom, 1.74 m dipper, backhoe bucket, operator and full fuel tank.

With 450 mm rubber tracks .........................................................................6900 kg With 450 mm steel tracks............................................................................7000 kg With 600 mm steel tracks............................................................................7100 kg

BOOMS Monobloc ..................................................................................................... 3.70 m Offset backhoe

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Length ....................................................................................... 1.74 m and 2.18 m

DOZER BLADE Width ............................................................................................................ 2.25 m Height........................................................................................................... 0.46 m Maximum raising height ............................................................................... 0.37 m Maximum depth ........................................................................................... 0.23 m

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SPECIFICATIONS

SAE capacity

85 L

105 L

130 L

160 L

230 L

310 L

365 L

Width (mm)

300

350

400

450

600

750

850

Weight (kg)

120

135

150

170

190

225

240

DITCH-CLEANING BUCKETS SAE capacity

260 L

300 L

Width (mm)

1600

1250

Weight (kg)

241

308

250 L

Width (mm)

300 - 1700

Weight (kg)

202

Template Name: OM_1_col Template Date: 1994_04_29

SAE capacity

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V-LINE BUCKET

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BACKHOE BUCKETS

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SPECIFICATIONS

MACHINE OVERALL DIMENSIONS Template Name: OM_1_col Template Date: 1994_04_29

With monobloc boom, 1.74 m dipper and backhoe bucket G

E

B

A F I

M K J

H D

L

C TRIM THIS EDGE

CS98M563

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(A) ................................................................................................................ 2.64 m (B) ................................................................................................................ 2.63 m (C) ................................................................................................................ 6.01 m (D) ................................................................................................................ 3.08 m (E) ................................................................................................................ 2.26 m (F) ................................................................................................................ 0.76 m (G) ................................................................................................................ 1.75 m (H) ................................................................................................................ 2.68 m (I)................................................................................................................. 2.05 m (J) ................................................................................................................. 1.70 m (K) ................................................................................................................ 0.45 m (L) (with 450 mm pads) ................................................................................ 2.15 m (L) (with 600 mm pads) ................................................................................ 2.30 m (L) (dozer blade) .......................................................................................... 2.25 m (M)................................................................................................................ 0.36 m

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SPECIFICATIONS

With offset backhoe, 1.74 m dipper and backhoe bucket

B F I

M K J

H D

L

C (A) ................................................................................................................ 2.82 m (B) ................................................................................................................ 2.63 m (C) ................................................................................................................ 6.10 m (D) ................................................................................................................ 3.08 m (E) ................................................................................................................ 2.26 m (F)................................................................................................................. 0.76 m (G) ................................................................................................................ 1.75 m (H) ................................................................................................................ 2.68 m (I) ................................................................................................................. 2.05 m (J) ................................................................................................................. 1.70 m (K) ................................................................................................................ 0.45 m (L) ................................................................................................................. 2.15 m (L) (dozer blade)........................................................................................... 2.25 m (M) ................................................................................................................ 0.36 m

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CS99K541

Template Name: OM_1_col Template Date: 1994_04_29

A

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E

G

SPECIFICATIONS

Template Name: OM_1_col Template Date: 1994_04_29

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SPECIFICATIONS

WORKING RANGE A F

C

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D

B E

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Backhoe equipment

G 1.74 m Dipper 2.18 m Dipper A (Maximum reach) .............................. 6.36 m ................................................... 6.81 m B (Maximum depth at tooth tips) .......... 4.15 m ................................................... 4.58 m C (Maximum height) ............................. 7.23 m ................................................... 7.66 m D (Dumping height)............................... 5.15 m ................................................... 5.56 m E (Maximum vertical depth).................. 3.49 m ................................................... 4.06 m F (Minimum radius) ............................... 1.75 m ................................................... 2.05 m G (Maximum reach at ground level)..... 6.22 m ................................................... 6.68 m

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Template Name: OM_1_col Template Date: 1994_04_29

CS98M562

SPECIFICATIONS

Offset backhoe equipment

F

C

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A

D

E TRIM THIS EDGE

B

CS99J506

H

H

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G

CS99J595

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Template Name: OM_1_col Template Date: 1994_04_29

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1.74 m Dipper A (Maximum reach) .............................................................................................. 6.38 m B (Maximum depth at tooth tips) .......................................................................... 4.13 m C (Maximum height) ............................................................................................. 7.22 m D (Dumping height)............................................................................................... 5.16 m E (Maximum vertical depth).................................................................................. 3.19 m F (Minimum radius) ............................................................................................... 2.10 m G (Maximum reach at ground level)..................................................................... 6.24 m H (LH/RH offset).................................................................................................... 1.13 m

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SPECIFICATIONS

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SPECIFICATIONS

MAXIMUM LOADS With monobloc boom Template Name: OM_1_col Template Date: 1994_04_29 TRIM THIS EDGE

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CS99K543

Loads are given in daN (1 daN = 1.02 kg), based on the foolwing assumptions : -

Bucket cylinder rod completely extended.

Load suspended from the bucket connecting rod eye.

Machine on a hard, flat level surface.

Full upperstructure swing. (*) Hydraulic system safety margin factor of 15%.

Stability safety margin factor of 33%.

The loads given are valid for the total working range height at the reach point indicated.

Distance ........................................................................ 1.50 m......... 3.00 m .......4.50 m Dipper (2.18 m) and backhoe bucket (190 Kg) ............2270*............. 1290* ....... 1070* Dipper (1.74 m) and backhoe bucket (210 Kg) ............2440*............. 1160* ......... 1100

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SPECIFICATIONS

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With offset backhoe boom (not in offset position)

CS99K544

-

Bucket cylinder rod completely extended.

Load suspended from the bucket connecting rod eye.

Machine on a hard, flat level surface.

Full upperstructure swing. (*) Hydraulic system safety margin factor of 15%.

Stability safety margin factor of 33%.

The loads given are valid for the total working range height at the reach point indicated.

Distance................................................................................................3.00 m..... 4.50 m Dipper (1.74 m) and backhoe bucket (210 Kg)....................................1180*........... 920

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Template Name: OM_1_col Template Date: 1994_04_29

Loads are given in daN (1 daN = 1.02 kg), based on the foolwing assumptions :

SPECIFICATIONS

HYDRAULIC BREAKER SPECIFICATIONS (optional) Template Name: OM_1_col Template Date: 1994_04_29

Weight (with standard 20 kg tool)..................................................................450 kg Impact force (CIMA method rating) .................................................................622 J Impact rate ..................................................................................... 600 - 1800 bpm Operating pressure ............................................................................ 100 - 130 bar Min. relief valve setting ...................................................................... 150 - 190 bar Max. relief valve setting .............................................................................. 220 bar Oil flow range .................................................................................... 50 - 100 L/mn Input power ....................................................................................... 33 kW (45 ch) Oil temperature .................................................................................... +40 - +60°C Maximum authorized oil temperature range.......................................... -20 - +80°C Noise level (certified by the manufacturer) as per european directive 86/662/EEC ........................................... 85 dB (A) 30 - 50 m

Tools

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CS99C641

Type

Length (mm)

Weight (kg)

mm

A = Chisel ....................................... 730.................................... 20 .......................... Ø 70 A = Long chisel .............................. 830.................................... 23 .......................... Ø 70 B = Moil point ................................. 730.................................... 20 .......................... Ø 70 B = Long moil point ....................... 830.................................... 23 .......................... Ø 70 C = Spade, parallel to boom......... 730.................................... 29 .................. width 200 D = Spade, transversal to boom .. 730.................................... 29 .................. width 200 E = Compaction plate.................... 610.................................... 54 ........................ Ø 330

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SPECIFICATIONS

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Overall dimensions

CS99E514

A............................................................................................................... 1657 mm B............................................................................................................... 1302 mm

D................................................................................................................. 581 mm E.......................................................................................................................Ø 70

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Template Name: OM_1_col Template Date: 1994_04_29

C................................................................................................................. 343 mm

ALPHABETICAL INDEX

Template Name: OM_1_col Template Date: 1994_04_29

A

D

Adjusting engine rocker arm clearance ............................. 174 Air conditioning ......................... 66, 188 Air conditioning control...................... 43 Air filter............................................ 157 Alternator ........................................ 196 Ashtray.............................................. 54 Audible warning device cut-out button................................ 39 Auxiliary hydraulic circuits............... 108

Dozer blade .................................... 202 Dozer blade control lever.................. 53

B

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Backhoe buckets............................. 203 Batteries.......................................... 194 Battery charge warning lamp ............ 47 Battery electrolyte level warning lamp ................................ 47 Before operating the machine........... 76 Boom and bucket right-hand control lever .................................. 50 Booms............................................. 202 Breaking techniques ....................... 110 Bringing the machine up to operating temperature .................. 83

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C Cab door ........................................... 34 Cab door sliding window ................... 55 Cab light............................................ 54 Checking for cylinder leakage......... 175 Choice of tools on a hydraulic breaker ....................................... 111 Cigarette lighter................................. 54 Coat hanger hook ............................. 54 Connecting booster batteries .......... 196 Control cancellation lever.................. 49 Control locking indicator lamp........... 48 Control locking switch ....................... 43 Cooling system ............................... 141

E Emergency hammer ......................... 55 Emergency shut-down switch ........... 43 Engine .................................... 138, 200 Engine coolant solution temperature indicator ................... 46 Engine coolant/hydraulic fluid temperature warning lamp ........... 47 Engine hood ..................................... 69 Engine idle speed selector ............... 41 Engine oil pressure warning lamp .... 46 Engine operation .............................. 84 Engine throttle button ....................... 39 Engine troubleshooting................... 189 Environment ................................... 122 F Fan and alternator drive belt........... 172 Fire extinguisher ............................. 188 Fluid and lubricant capacities and specifications.............................. 123 Fluids and lubricants....................... 119 Fuel level indicator............................ 46 Fuel level warning lamp .................... 47 Fuel system .................................... 144 Fuel tank........................................... 68 Fuel tank filler pump ......................... 74 Fuel tank filter ................................. 174 Fuses .............................................. 192 G Grease points ................................. 124 Greasing the hydraulic breaker ...... 134 Greasing the swing reduction gear ............................ 135 Greasing the turntable teeth ........... 135

D

H

Decals ............................................... 26 Dipper ............................................. 202 Dipper and upperstructure swing lefthand control lever ......................... 50

Hand signals..................................... 30 Handling the hydraulic breaker....... 110 Handling the machine ....................... 94 Heating and ventilation ..................... 63

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O

Heating and ventilation controls ........ 64 High speed travel indicator lamp ....... 48 Horn switch ....................................... 45 Hourmeter ................................. 43, 115 Hydraulic breaker intervals..............118 Hydraulic breaker specifications ..... 212 Hydraulic system ..................... 148, 200

Operating the machine on sloping ground .......................................... 98 Operator’s compartment controls ..... 36 Operator’s seat ................................. 57 Optional tool supply valves ............... 73 Optional tool valves .......................... 72

Indicators and gauges .....................201 Inspecting and cleaning the machine ................................ 174 Inspecting and servicing the quick coupler ........................................187 Instrument console ............................46 Intervals........................................... 116 L

P Parking the machine ....................... 103 Plastic and resin parts .................... 175 Pre-heating indicator lamp ................ 48 Q Quick implement installation and removal....................................... 100 R

Noise levels ............................... 11, 202

Radiator and oil cooler .................... 171 Rear view mirror ............................... 68 Releasing pressure in the hydraulic system ........................................ 146 Replacing a backhoe bucket........... 178 Replacing a hydraulique hammer ... 184 Replacing a tool bushing on a hydraulic breaker ................ 182 Replacing a tool on a hydraulic breaker ................ 180 Replacing a tooth tip on a backhoe bucket .................. 176 Right, left, front and rear of the machine ................................ 8 Right-hand control arm ..................... 38 Right-hand side hood........................ 69 Roof hatch ........................................ 55 Run-in period .................................... 79

O

S

Official documents............................... 7 Operating the backhoe bucket .......... 99 Operating the machine in cold weather..............................85 Operating the machine in hot weather ............................... 85 Operating the machine in water ........ 97

Safety devices ................................ 201 Safety instructions ............................ 14 Safety valve ...................................... 71 Servicing instructions ...................... 114 Special conditions of use on a hydraulic breaker ................ 112 Starter motor ................................... 197 Starter switch .................................... 39

Left-hand control arm ........................ 42 Levels .............................................. 136 Load handling.................................... 95 Load handling chart........................... 96 Load handling eye ............................. 71 Location of controls and associated components .................................. 36 Lower panels..................................... 70 M Machine components ........................ 12 Machine operation.......................77, 87 Machine overall dimensions ............ 204 Machine travel ...................................89 N

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I

Template Name: OM_1_col Template Date: 1994_04_29

H

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ALPHABETICAL INDEX

ALPHABETICAL INDEX

Template Name: OM_1_col Template Date: 1994_04_29 TRIM THIS EDGE

S

U

Starting the engine............................ 80 Steps and access handles ................ 35 Stopping the engine .......................... 86 Storage tray ...................................... 55 Storing the machine ........................ 198 Sun shield ......................................... 56

Undercarriage ................................. 201 Upperstructure swing locking indicator lamp................... 47 Upperstructure swing locking switch ............................... 43 Using optional tools ........................ 106

T

V

To the owner ....................................... 6 Towing the machine ........................ 105 Track rollers and idler wheels ......... 161 Tracks ............................................. 164 Transporting the machine ................. 92 Travel control levers and pedals ....... 51 Travel reduction gears .................... 162 Travel speed selector pedal.............. 52 Type, serial number and year of manufacture.................................. 10

Ventilation control ............................. 43 W Warning and indicator lamps .......... 201 Wear limits on a hydraulic breaker ....................................... 186 Weights........................................... 202 Welding on the machine ................. 179 Windshield ........................................ 60 Windshield washer reservoir ............ 70 Windshield washer switch ................ 39 Windshield wiper switch ................... 39 Working light switch.......................... 41 Working mode selector..................... 41 Working range ................................ 207

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

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

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CASE TECHNICAL MANUALS

Your CASE Dealer can deal with orders for operator’s manuals, parts catalogues and service manuals.

Template Name: OM_1_col Template Date: 1994_04_29

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Always give the type and serial number of your machine so that your CASE Dealer can supply you with the right manuals for your machine.

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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.

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Template Name: OM_1_col Template Date: 1994_04_29

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Printed in France

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