Case 9046 Crawler Excavator Operator's Manual Cre 6-7781 GB - PDF DOWNLOAD

Operator’s Manual

Cre 6-7781 GB Replaces Cre 6-7780 GB

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Template Name: OM_1_col Template Date: 1994_04_29

9046 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 6-7781 GB Issued February 1999 (Revised December 1999)

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TABLE OF CONTENTS

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

CONTROLS/INSTRUMENTS/ACCESSORIES ........................................... 34 - 80 CAB DOOR .................................................................................................... 34 STEPS AND ACCESS HANDLES ................................................................. 35 OPERATOR’S COMPARTMENT CONTROLS ............................................. 36 OPERATOR’S SEAT ..................................................................................... 61 WINDSHIELD ................................................................................................ 64 HEATING AND VENTILATION ...................................................................... 67 HEATING AND VENTILATION CONTROLS ................................................. 68 AIR CONDITIONING ..................................................................................... 70 FUEL TANK ................................................................................................... 72 REAR VIEW MIRROR ................................................................................... 72 FRONT STORAGE BOX ............................................................................... 73 SIDE DOORS ................................................................................................ 73 ENGINE HOOD ............................................................................................. 74 LOWER PANELS ........................................................................................... 75 WINDSHIELD WASHER RESERVOIR ......................................................... 75 LOAD HANDLING EYE ................................................................................. 76 SAFETY VALVE ............................................................................................ 77 SELECTOR BLOCKS .................................................................................... 77 OPTIONAL TOOL SUPPLY VALVES ............................................................ 78 FUEL TANK FILLER PUMP ........................................................................... 79 OPERATING INSTRUCTIONS .................................................................. 81 - 121 BEFORE OPERATING THE MACHINE ........................................................ 81 MACHINE OPERATION ................................................................................ 82 RUN-IN PERIOD ............................................................................................ 84 STARTING THE ENGINE .............................................................................. 85 BRINGING THE MACHINE UP TO OPERATING TEMPERATURE ............. 89 ENGINE OPERATION ................................................................................... 90 OPERATING THE MACHINE IN COLD WEATHER ..................................... 91 OPERATING THE MACHINE IN HOT WEATHER ........................................ 91 STOPPING THE ENGINE ............................................................................. 92 MACHINE OPERATION ................................................................................ 93 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 9046 HYDRAULIC CRAWLER EXCAVATOR .................................................

TO THE OWNER .............................................................................................

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

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Operating instructions (continued) MACHINE TRAVEL ....................................................................................... 95 TRANSPORTING THE MACHINE ................................................................ 98 HANDLING THE MACHINE ........................................................................ 102 LOAD HANDLING ....................................................................................... 103 LOAD HANDLING CHART .......................................................................... 105 OPERATING THE MACHINE IN WATER ................................................... 106 OPERATING THE MACHINE ON SLOPING GROUND ............................. 107 OPERATING THE BACKHOE BUCKET ..................................................... 108 QUICK IMPLEMENT INSTALLATION AND REMOVAL .............................. 109 PARKING THE MACHINE ........................................................................... 112 TOWING THE MACHINE ............................................................................ 114 USING OPTIONAL TOOLS ......................................................................... 115 AUXILIARY HYDRAULIC CIRCUITS .......................................................... 117 HANDLING THE HYDRAULIC BREAKER .................................................. 119 BREAKING TECHNIQUES ON A HYDRAULIC BREAKER ........................ 119 CHOICE OF TOOLS ON A HYDRAULIC BREAKER .................................. 120 SPECIAL CONDITIONS OF USE ON A HYDRAULIC BREAKER .............. 121

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SERVICING INTERVALS ........................................................................ 122 - 127 SERVICING INSTRUCTIONS ..................................................................... 122 HOURMETER .............................................................................................. 123 INTERVALS ................................................................................................. 124 HYDRAULIC BREAKER INTERVALS ......................................................... 127

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LUBRICATION/FILTERS/FLUIDS .......................................................... 128 - 169 FLUIDS AND LUBRICANTS ........................................................................ 128 ENVIRONMENT .......................................................................................... 131 FLUID AND LUBRICANT CAPACITIES AND SPECIFICATIONS .............. 132 GREASE POINTS ....................................................................................... 134 GREASING THE HYDRAULIC BREAKER .................................................. 138 GREASING THE TURNTABLE TEETH ...................................................... 139 LEVELS ....................................................................................................... 140 ENGINE ....................................................................................................... 142 COOLING SYSTEM .................................................................................... 145 FUEL SYSTEM ............................................................................................ 148 RELEASING PRESSURE IN THE HYDRAULIC SYSTEM ......................... 150 HYDRAULIC SYSTEM ................................................................................ 152 AIR FILTER ................................................................................................. 161 SWING REDUCTION GEAR ....................................................................... 165 TRACK ROLLERS AND IDLER WHEELS .................................................. 167 TRAVEL REDUCTION GEARS ................................................................... 168

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ELECTRICAL SYSTEM ........................................................................... 198 - 203 FUSES ......................................................................................................... 198 BATTERIES ................................................................................................. 200 CONNECTING BOOSTER BATTERIES ..................................................... 202 ALTERNATOR ............................................................................................. 202 STARTER MOTOR ...................................................................................... 203 STORAGE ............................................................................................... 204 - 205 STORING THE MACHINE ........................................................................... 204 SPECIFICATIONS ................................................................................... 206 - 220 ENGINE ....................................................................................................... 206 HYDRAULIC SYSTEM ................................................................................ 206 UNDERCARRIAGE ..................................................................................... 207 SAFETY DEVICES ...................................................................................... 207 LAMPS/INDICATORS .................................................................................. 207 NOISE LEVELS ........................................................................................... 207 WEIGHTS .................................................................................................... 208 MONOBLOC BOOM .................................................................................... 208 DIPPER ........................................................................................................ 208 BACKHOE BUCKET .................................................................................... 209 MACHINE OVERALL DIMENSIONS ........................................................... 210

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MAINTENANCE/ADJUSTMENTS ........................................................... 170 - 197 TRACKS ...................................................................................................... 170 RADIATOR AND OIL COOLER ................................................................... 174 FAN AND ALTERNATOR DRIVE BELTS .................................................... 176 FUEL TANK FILTER .................................................................................... 178 AIR TANK .................................................................................................... 178 ADJUSTING ENGINE ROCKER ARM CLEARANCE ................................. 179 INSPECTING AND CLEANING THE MACHINE ......................................... 179 CHECKING FOR CYLINDER LEAKAGE .................................................... 180 PLASTIC AND RESIN PARTS .................................................................... 180 REPLACING A TOOTH TIP ON A BACKHOE BUCKET ............................. 181 REPLACING A BACKHOE BUCKET ........................................................... 183 SHIMMING THE BACKHOE BUCKET ........................................................ 184 REPLACING A TOOL ON A HYDRAULIC BREAKER ................................ 185 REPLACING A TOOL BUSHING ON A HYDRAULIC BREAKER ............... 187 REPLACING A HYDRAULIC BREAKER ..................................................... 189 WEAR LIMITS ON A HYDRAULIC BREAKER ............................................ 191 INSPECTING AND SERVICING THE QUICK COUPLER .......................... 192 WELDING ON THE MACHINE .................................................................... 193 FIRE EXTINGUISHER ................................................................................. 193 AIR CONDITIONING ................................................................................... 194 ENGINE TROUBLESHOOTING .................................................................. 195

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Specifications (continued) WORKING RANGE .....................................................................................

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

HYDRAULIC BREAKER ..............................................................................

MATERIAL DENSITY/HANDLING TABLE ..................................................

DENSITY OF VARIOUS SOILS AND MATERIALS ...................................

211 212 214 217 218

ALPHABETICAL INDEX .......................................................................... 221 - 223

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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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CP99B024

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9046 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.

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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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

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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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1 FRONT 2 REAR 3 RIGHT-HAND SIDE

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

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IDENTIFICATION NUMBERS/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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CS99A668

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

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

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

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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 NUMBERS/MACHINE COMPONENTS

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(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

CS99A856

CS98N513

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

Quick coupler (optional)

IDENTIFICATION NUMBERS/MACHINE COMPONENTS

MACHINE COMPONENTS

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CP99B024

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The 9046 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 Hydraulic reservoir Fuel tank

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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).

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.

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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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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.

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.

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.

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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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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.

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

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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.

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

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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.

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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.

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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.

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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.

It is mandatory to remove the counterweight before undertaking any travel without the attachment or transporting the machine without the attachment.

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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.

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

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

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

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.

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.

When climbing into or out of the operator’s compartment, it is mandatory for the control cancellation lever and the left-hand control arm to be in raised position. 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.

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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 • When working on a public highway, use • Always make

SAFETY/DECALS/HAND SIGNALS

• Template Name: OM_1_col Template Date: 1994_04_29

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When climbing into or out of 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.

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Never jump down from the machine.

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

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

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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.

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.

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For machines up to serial number DCH4600138, never use the connecting rod load handling eye for lifting loads weighing more than 12 000 kg (11 765 daN), attach the load to the connecting rod/bucket linkage pin. For machines with serial numbers DCH4600139 and above, whatever the weight of the load, attach the load to the connecting rod load handling eye.

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SAFETY/DECALS/HAND SIGNALS

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

1. Working area.

2. Safety area.

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When parking the machine, proceed as follows :

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

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

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

5. Lock the cab door.

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

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

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

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PARKING THE MACHINE

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SAFETY AREA • The safety area is the space necessary

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BEFORE USING THE HYDRAULIC BREAKER (optional) • Do not attempt to operate this hydraulic • Every day, inspect the hydraulic breaker 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.

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

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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.

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USING THE HYDRAULIC BREAKER (optional) • Protect yourself and the vicinity from fly- • Do not operate the hydraulic hammer if ing chips of rock.

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

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

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Move everybody away before operating the hydraulic breaker.

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

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

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

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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.

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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.

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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

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

made 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.

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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 until it is 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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•

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

Hydraulic breaker (optional) • The hydraulic breaker incorporates one accumulator. This accumulator remain constantly under pressure, event when the hydraulic breaker is removed from the machine. Do not try to service the accumulator. All service work on the accumulator 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.

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

PREVENTION OF FIRE OR EXPLOSIONS • Engine fuel can cause an explosion or • Sparks can fly from the electrical sysTemplate Name: OM_1_col Template Date: 1994_04_29

a 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.

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

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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.

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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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SAFETY/DECALS/HAND SIGNALS

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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SAFETY/DECALS/HAND SIGNALS

DECALS Template Name: OM_1_col Template Date: 1994_04_29

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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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SAFETY/DECALS/HAND SIGNALS

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 accumulator and remind you that, whatever the service work, the accumulator will be under pressure. See your CASE Dealer.

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Hydraulic breaker (optional)

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SAFETY/DECALS/HAND SIGNALS

HAND SIGNALS Template Name: OM_1_col Template Date: 1994_04_29

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

Start the engine

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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SAFETY/DECALS/HAND SIGNALS

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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CONTROLS/INSTRUMENTS/ACCESSORIES

!

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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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.

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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.

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

1 2

CP99B025

1 2

CP99B026

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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2

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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.

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Location of controls and associated components 14

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12 11 10

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9 8

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4

3

2

6 CS98N546

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CONTROLS/INSTRUMENTS/ACCESSORIES 1 Operator’s seat

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

13 Cab interior lighting

Template Name: OM_1_col Template Date: 1994_04_29

14 Roof hatch

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2 Cab door unlatching lever

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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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B9407058

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1. CONTROL ARM TILT ADJUSTMENT LEVER - This lever enables the operator to tilt the angle of the control arm to suit his convenience. Move the lever to the right and hold it in this position. Tilt the control arm to the required position and then release the lever.

2. 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.

NOTE: The starter switch key is also used to lock the cab door, the engine hood, the front storage compartment, the side doors and the fuel tank cap.

3. 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.

4. AUDIBLE WARNING DEVICE CUT-OUT BUTTON - Press this button to turn off the audible warning device. if the audible warning device sounds, immediately read the message appearing on the systems display panel . When the audible warning device is not working, this button also has another function. Press the button to test the lamps and indicators on the systems display panel and control arms for correct operation.

5. WORKING MODE SELECTOR - This allows one of four working modes to be selected. “S” (standard) mode for ordinary duties; “H” (heavy) mode for hard work or when there is an increase in work load; “L” (light) mode for precision work requiring lower operating speed and “F” (fine) mode for load handling, for greater lifting capacity at reduced operating speed. See “Load handling” in the “Operating Instructions” Section.

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NOTE: If there is no change in engine speed, press and release the engine automatic idle speed selector. (See item 14).

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CONTROLS/INSTRUMENTS/ACCESSORIES

NOTE: Each working mode has a corresponding message and letter which appear on the systems display panel. See items 4 and 11 under “Systems display panel”.

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Template Name: OM_1_col Template Date: 1994_04_29

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

CONTROLS/INSTRUMENTS/ACCESSORIES

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

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CONTROLS/INSTRUMENTS/ACCESSORIES RADIO (optional) COMPARTMENT.

7. AUXILIARY CONTROLS (clock setting and emergency manual controls) - See “Right-hand control arm rear controls”.

8. HORN VOLUME LEVEL SWITCH - This switch makes it possible to select one of two different horn volume levels. If the lamp in the switch is not on, the horn volume level will be low when the left-hand control lever horn button is pressed. If the lamp is on, the volume level will be high. Press the switch to select the required horn volume level.

9. ATTACHMENT CUSHION CONTROL SWITCH (boom and dipper) - This switch makes it possible to select one of two different types of attachment operation. When the lamp in the switch is not on, attachment functions will be cushioned and come to a smooth halt. If the lamp is on, attachment functions will come to a sharp halt.

10. ROTATING BEACON - This switch controls the rotating beacon. Press the switch once the rotating beacon and the indicator lamp in the switch will light up. When the switch is pressed again, the rotating beacon goes out.

11. 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.

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

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NOTE: When starting the engine, the sharp halt type of attachment operation (with the lamp off) is automatically selected.

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6.

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

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Template Name: OM_1_col Template Date: 1994_04_29

12. WINDSHIELD WIPER SWITCH - This switch has three positions : “Off”, “Intermittent” and “Continuous”. Press the switch for intermittent operation, the first lamp comes on. Press the switch again to obtain continuous operation, the other lamp comes on.

Press the switch once more for the function to cease.

CONTROLS/INSTRUMENTS/ACCESSORIES

Right-hand control arm (continued) 16

Template Name: OM_1_col Template Date: 1994_04_29

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B9407058

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13. 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.

15. ENGINE AUTOMATIC RETURN TO IDLE SPEED SELECTOR - This control makes it possible to select, or cancel, automatic engine return to idle speed. When starting the engine, the automatic return to idle speed function is automatically selected and the lamp in the control is not on. This means that if you temporarily stop operating the controls, for about 15 seconds, then the engine will automatically return to idle speed. To make the engine revert to its original speed, press control (14) on the right-hand control lever. To cancel automatic engine return to idle speed, press the control and the indicator lamp in the control lamp will come on.

16. POWER UP SWITCH - Press and release this switch to obtain maximum attachment power for about 8 seconds; the message “Power up” will appear on the systems display panel. To cancel, press and release the control; the message on the systems display panel will disappear. See item 1 under “Systems display panel”.

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14. ENGINE IDLE SPEED SELECTOR - This control makes it possible to select automatic engine idle speed without having recourse to the engine throttle button.

Press and release the control for the engine automatically to go into idle speed; the message “Eng. idling” will appear on the systems display panel. When the control is pressed and released once more the engine will revert to its original speed and the message on the systems display panel will disappear. See item 11 under “Systems display panel”.

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CONTROLS/INSTRUMENTS/ACCESSORIES

Template Name: OM_1_col Template Date: 1994_04_29

NOTE: This switch is only operational when “H” (heavy) and “S” (standard) modes are selected (see item 5).

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CONTROLS/INSTRUMENTS/ACCESSORIES

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

1 5 TRIM THIS EDGE

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CS99J521

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4

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2.

VENTILATION CONTROL - See “Heating and ventilation”.

3.

AIR CONDITIONING CONTROL - See “Air conditioning”.

4. CONTROL LOCKING SWITCH - This switch is used to lock all machine hydraulic functions. When this switch is pressed, all attachment, travel and swing functions are locked, the control levers and pedals are inoperational and the “Control locking” indicator lamp will come on. When the switch is pressed again, all functions become operational once more and the indicator lamp goes out. See item 3 under “Systems display panel”.

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 systems display panel goes out. See item 2 under “Systems display panel”.

6. EMERGENCY SHUT DOWN SWITCH - This switch is used to shut down the engine in a case of emergency or if it is not possible to stop the engine using the starter switch key. When this switch is pressed, the engine stops, the audible warning device sounds, the indicator lamp in the switch comes on and the message “Emergency stop” will be displayed. To start the engine again, press the switch once more; the message on the systems display panel will disappear. Then turn the starter switch key to start the engine. See item 11 under “Systems display panel”.

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

8

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12

11

CS99J521

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10

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7. CONTROL ARM TILT ADJUSTMENT AND FUNCTION CANCELLATION LEVER - This lever makes it possible for the operator to adjust the tilt angle of the control arm to suit his convenience. Move the lever to the right and hold it in this position. tilt the control arm to the required position and then release the lever. This lever also makes it possible to raise the control arm completely, so as to cancel all machine functions. In raised position, the “Control locking” indicator lamp will light up on the systems display panel. See item 3 under “Systems display panel”.

!

8.

WARNING : When entering or leaving the operator’s compartment, it is imperative for the left-hand control arm to be in raised position. Never forget this basic requirements.

HORN - To operate the horn, press the tip of the left-hand control lever.

IMPORTANT: Always sound the horn before operating the machine.

9. AUXILIARY ATTACHMENT CONTROL SWITCH (optional) - This switch selects single or dual pump flow for the auxiliary attachments. Push the top position for single pump flow (bucket and breaker attachments). Push the bottom for dual pump flow (crushers or other double acting attachments).

10. BOOM PRIORITY SWITCH - The two switch positions are “ON” and “OFF”.

When trenching and swinging the load away from the trench, use the “OFF” position.

Then, when trenching and dumping the load close to the trench, use “ON”. When in the “ON” position, more pump flow is given to the boom circuit and less to the swing.

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NOTE: Two different horn volume levels may be selected, low or loud. See item 8 under “Right-hand control arm”.

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CONTROLS/INSTRUMENTS/ACCESSORIES

12. 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.

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

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Template Name: OM_1_col Template Date: 1994_04_29

11. 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.

CONTROLS/INSTRUMENTS/ACCESSORIES

Systems display panel Template Name: OM_1_col Template Date: 1994_04_29

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7 B9407082

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WARNING : The display panel indicates the machine’s condition and alerts 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 display panel can be damaged by water. Take care that it doesn’t get wet during rainy weather or when washing the machine.

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

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1. TRAVEL SPEED INDICATOR LAMPS - These lamps light up to show the travel speed selected by the selector pedal, see “Travel speed selector pedal”.

The left-hand lamp lights up when high speed is selected.

The middle lamp lights up when medium speed is selected.

The right-hand lamp lights up when low speed is selected.

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

3. CONTROL LOCKING INDICATOR LAMP - This lamp lights up when the “Control locking switch” is operated. See item 4 under “Left-hand control arm”. It also lights up when the control cancellation lever and the left-hand control arm are in raised position. See “Control cancellation lever” and item 7 under “Left-hand control arm”.

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

6. ENGINE COOLANT TEMPERATURE INDICATOR - This indicator has three zones. The white zone shows the engine coolant temperature is low. The green zone shows the engine coolant temperature is normal. The red zone shows the engine coolant temperature is high. The actual coolant temperature is represented by an increasing or diminishing number of luminous horizontal bar segments. When the horizontal bar segments reach the red zone, the audible alarm device sounds and the message “Over heat” (see item 11) is displayed. Shut down the engine, remove the starter switch key and find the cause of the problem.

7. HYDRAULIC FLUID TEMPERATURE INDICATOR - This indicator has three zones. The white zone shows the hydraulic fluid temperature is low. The green zone shows the hydraulic fluid temperature is normal. The red zone shows the hydraulic fluid temperature is high. The actual hydraulic fluid temperature is represented by an increasing or diminishing number of luminous horizontal bar segments. When the horizontal bar segments reach the red zone, the audible alarm device sounds and the message “Over heat” (see item 11) is displayed. 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.

8. FUEL LEVEL INDICATOR - This indicator has two zones. The green zone shows that the quantity of fuel in the fuel tank is normal. The red zone shows that it is necessary to add more fuel. The fuel quantity is represented by luminous horizontal bar segments which diminish as fuel is consumed. If the horizontal bar segments reach the red zone, the audible alarm device sounds and the message “low fuel level (see item 11) is displayed.

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

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5. CLOCK - This shows hours (1-12) and minutes. to adjust the time, see items (1) and (2) under “Right-hand control arm rear controls”.

Template Name: OM_1_col Template Date: 1994_04_29

4. WORKING MODE INDICATOR - This indicator shows the initial of the working mode selected by the control on the right-hand control arm. See item 5 under “Righthand control arm”.

The letter “S” appears to indicate selection of “S” (standard) mode.

The letter “H” appears to indicate selection of “H” (heavy) mode.

The letter “L” appears to indicate selection “L” (light) mode.

The letter “F” appears to indicate selection “F” (fine) mode.

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CONTROLS/INSTRUMENTS/ACCESSORIES

CONTROLS/INSTRUMENTS/ACCESSORIES

Systems display panel (continued) Template Name: OM_1_col Template Date: 1994_04_29

11

9

10 B9407082

9. WARNING SYMBOL - When this symbol appears, the audible alarm device sounds and a message is displayed. If the symbol appears during operation, read the accompanying message, move the machine to a safe area, shut down the engine, remove the starter switch key and find the cause of the problem.

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10. BRIGHTNESS CONTROL BUTTON - Turn this clockwise to increase the brightness of the systems display panel, or counterclockwise to dim.

11. MESSAGE DISPLAY SCREEN - As you operate the machine, this screen will display symbols and messages which change to keep you informed of the machine’s condition. The symbols and messages are listed below along with brief explanations.

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ENG. PRE HEAT - This message is displayed when the engine is cold. Turn the starter switch key to “HEAT” position. Release the key when the audible alarm device sounds. See item 2 under “Right-hand control arm”.

AUTO WARM UP - This message shows that engine temperature is automatically rising to operating temperature. It disappears once the engine has reached operating temperature or when the engine idle speed selector, the throttle control button or a control lever is operated. See items 3 and 15 under “Right-hand control arm”.

ENG. IDLING - This message shows that the engine idle speed selector has been operated and that the engine is running at idle speed. See item 14 under “Right-hand control arm”.

POWER UP - This message shows that maximum attachment power (for 8 seconds) has been requested. See item 16 under “Right-hand control arm”.

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CONTROLS/INSTRUMENTS/ACCESSORIES

LIGHT MODE - This message shows that LIGHT has been selected. See item 5 under “Right-hand control arm”.

FINE MODE - This message shows that FINE has been selected. See item 5 under “Right-hand control arm”.

EMERGENCY STOP - This message shows that the emergency shut down switch has been operated and the audible warning device sounds. See item 6 under “Left-hand control arm”.

LOW FUEL LEVEL - This message shows that the level of fuel in the fuel tank is low and that fuel must be added. The audible alarm device also sounds. See item 8.

LOW COOLANT - This message shows that the engine coolant level is low.

The audible warning device also sounds. Shut down the engine, remove the starter switch key, allow the system to cool down and then check the coolant level in the expansion reservoir and the radiator. See “Cooling System” in the “Lubrication/Filters/Fluids” Section.

BATTERY LEVEL - This message shows that the battery electrolyte level is low. The audible warning device also sounds. Shut down the engine, remove the starter switch key and check the battery electrolyte level. See “Batteries” in the “Electrical System” Section.

AIR FILTER - This message shows that the air filter elements must be cleaned or replaced. The audible alarm device also sounds. See “Air Filter” in the “Lubrication/Filters/Fluids” Section.

LOW OIL PRESS - This message shows that the engine oil level is low. The audible alarm device also sounds. Shut down the engine, remove the starter switch key and check the level. See “Engine” in the “Lubrication/Filters/Fluids” Section.

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BOOM PRIORITY - This message shows that the Boom Priority button has been pushed. Maximum hydraulic pump flow is supplied to the boom for increased digging speed when trenching. See item 10 under “Left-hand control arm”.

Template Name: OM_1_col Template Date: 1994_04_29

STANDARD MODE - This message shows that STANDARD has been selected. See item 5 under “Right-hand control arm”.

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HEAVY MODE - This message shows that HEAVY mode has been selected.

See item 5 under “Right-hand control arm”.

CONTROLS/INSTRUMENTS/ACCESSORIES

Template Name: OM_1_col Template Date: 1994_04_29

ENG. OIL FILTER - This shows that the engine oil filters are restricted. The audible alarm device also sounds. Shut down the engine, remove the starter switch key and replace the filters. See “Engine” in the “Lubrication/Filters/Fluids” Section.

OVER HEAT - This message shows that the temperature of the engine coolant or the hydraulic fluid is too high (see items 6 and 7). The audible alarm device also sounds. Reduce engine speed. If the temperature does not drop, shut down the engine, remove the starter switch key and find the cause of the problem.

ALTERNATOR - This message shows that the alternator is defective. The audible alarm device also sounds. Shut down the engine, remove the starter switch key and check the alternator. See your CASE Dealer.

ELEC. PROBLEM - This message shows that there is a fault in the electrical system. The audible alarm device also sounds. Shut down the engine, remove the starter switch key and find the cause of the problem, or see your CASE Dealer. See the “Electrical System” Section.

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HYD. TANK PRESS. - This message shows that pressure in the hydraulic reservoir is low. The audible alarm device also sounds. Shut down the engine, remove the starter switch key and find the cause of the problem.

NOTE: To stop the audible alarm device, press the control on the right-hand control arm. See item 4 under “Right-hand control arm”.

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CONTROLS/INSTRUMENTS/ACCESSORIES

4

1 5

CP98N009

2. CLOCK MINUTE ADJUSTMENT - Press and hold down this control to increase the number of minutes rapidly. Press and release the control to change the minutes one by one.

3. AUXILIARY CONTROL (backup) SWITCH - If, as a result of a problem, certain controls will not function (engine speed, upperstructure swing unlocking, control unlocking), this switch can be used on an emergency basis to restore manual control.

During normal machine operation, the switch should be in off position (with the indicator lamp OFF). In case of an emergency, press the switch and the indicator lamp will come on. In this position, control locking and upperstructure swing functions are inoperational, working mode goes directly into “L” (light), travel speed goes directly into medium and all the functions on the systems display panel are inoperational. To adjust engine speed, press and hold down the control (4) to decrease speed and release the control when the required speed is obtained. To increase speed, press and hold down control (5) and release it when the required speed is obtained.

NOTE: To start the engine when the backup system is in use, press control (5) several times before starting the engine.

IMPORTANT: This backup system is only to be used in case of an emergency, to move the machine to a safe area or a workshop for the necessary repairs to be made.

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1. CLOCK HOUR ADJUSTMENT - Press and hold down this control to increase the number of hours rapidly. Press and release the control to change the hours one by one.

Template Name: OM_1_col Template Date: 1994_04_29

3

2

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Right-hand control arm rear controls

CONTROLS/INSTRUMENTS/ACCESSORIES

Control cancellation lever Template Name: OM_1_col Template Date: 1994_04_29

CK98M009

CK98M010

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

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

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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 “Systems display panel” (item 3).

!

WARNING: When entering or leaving the operator’s compartment, it is imperative for the control cancellation lever and the lefthand control arm to be in raised position. Never forget this basic requirement.

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CONTROLS/INSTRUMENTS/ACCESSORIES

Boom and bucket righthand control lever 5

1 6 2

8

4 7 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

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.

2 3

5 8

1

CS98N547

5.

6.

7.

8.

CS98N547

1.

2.

3.

4.

6

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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Template Name: OM_1_col Template Date: 1994_04_29

4

7

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CS98M564

3

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Dipper and upperstructure swing lefthand control lever

CONTROLS/INSTRUMENTS/ACCESSORIES

Travel control levers and pedals Template Name: OM_1_col Template Date: 1994_04_29

9

10

11

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.

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”.

CD98N008

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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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9

10

Option pedal

11

CD98N008

This pedal is used for optional tools such as hydraulic hammers, etc. See “Using optional tools” in the “Operating Instructions” Section.

12

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

CS99B514

9. The left-hand track moves forwards.

10. The left-hand moves to the rear.

11. The right-hand track moves forwards.

12. The right-hand track moves to the rear.

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Quick coupler locking/ unlocking control (optional) 1

2

CD98N008

This pedal allow one of three possible travel speeds to be selected.

3

Slow speed, for slow travel or when maximum power is required (0 to 2.0 kph).

Medium speed, for travel over rough ground, climbing slopes or maximum power (0 to 2.8 kph).

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.

High speed, for travel on flat or gently undulating ground (0 to 5.0 kph).

When starting the engine, medium speed is automatically selected.

(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 change from one speed to another, press the pedal once and then release it.

NOTE: For each speed a corresponding indicator lamp lights up on the systems display panel. See item 1 under “Systems display panel”.

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

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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.

Template Name: OM_1_col Template Date: 1994_04_29

Travel speed selector pedal

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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

CP98N010

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 to the right at the rear of the cab.

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

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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

Emergency hammer

A23887

CP98N011

This hammer, located on the cab lefthand upright, 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

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Roof hatch

Template Name: OM_1_col Template Date: 1994_04_29

CP98N012

CP98M004

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

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CONTROLS/INSTRUMENTS/ACCESSORIES

Beverage holder Template Name: OM_1_col Template Date: 1994_04_29

CP98N010

This is for holding drinks, amongst other things, and is located to the rear of the cab.

Sun shield TRIM THIS EDGE

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CK99J001

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

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CONTROLS/INSTRUMENTS/ACCESSORIES

8 5

4 1 9 2

7

CD98N013

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

!

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 the 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

CD98N015

To ajdust 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.

CD98N015

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

9 7

CD98N017

CD98N015

Pull the lever (7) upwards, and slide the seat and control arm assembly to the desired position, then release the lever.

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

Headrest adjustment

To release the seat belt, press down on the releasing lever (9).

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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Sit comfortably in the seat, pull out a long section of belt and engage it in the fastening system (9).

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Seat and control arm assembly fore and aft adjustment

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

Template Name: OM_1_col Template Date: 1994_04_29

8

CD98N016

The headrest (8) can be adjusted upwards and downwards and backwards and forwards.

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

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CONTROLS/INSTRUMENTS/ACCESSORIES

WINDSHIELD Template Name: OM_1_col Template Date: 1994_04_29

!

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 1

STEP 3

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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

A23886

Release the left-hand lock and tilt it downwards.

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.

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CONTROLS/INSTRUMENTS/ACCESSORIES STEP 5

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

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

CP99B080

CS99J511

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

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

Template Name: OM_1_col Template Date: 1994_04_29

Air vents

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Windshield defroster

Heater valve

CP98N010

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

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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

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 (C) to select the required position. The corresponding indicator lamp comes on.

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CP99J004

B

E

C

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.

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 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 STEP 6

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

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

Template Name: OM_1_col Template Date: 1994_04_29

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

!

CD99B003

The fuel tank capacity is 650 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.

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

Never smoke during refuelling.

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

NOTE: Use the starter switch key to lock the fuel cap.

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.

CP99B081

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CONTROLS/INSTRUMENTS/ACCESSORIES

Use the handle to open the storage box and tilt the cover completely upwards.

To close, move the support strut back slightly and tilt the cover downwards.

NOTE: Use the starter switch key to lock the storage box cover.

CP99B027

!

WARNING: Before undertaking any travel, make sure the storage box cover is properly closed.

SIDE DOORS Right-hand door

Left-hand doors

A24672

CP99B028

The right-hand door gives access to a number of hydraulic components (filters, etc...).

The left-hand doors are mainly for obtaining access to the batteries, air filter, radiator and oil cooler, etc...

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This is to the right, in front of the upperstructure frame. It is used for storing emergency parts.

Template Name: OM_1_col Template Date: 1994_04_29

The storage box also gives access to the windshield washer reservoir and to the fuel tank filler pump.

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FRONT STORAGE BOX

CONTROLS/INSTRUMENTS/ACCESSORIES

Template Name: OM_1_col Template Date: 1994_04_29

Use the outside handles to open the doors. To hold the doors, open, remove the strut from its storage position and install it in the hole provided. When closing, put the strut back into storage position.

!

WARNING: Always install the strut when the doors are open.

!

WARNING: Never leave tools or other objects behind the side doors.

!

WARNING: Before undertaking any travel, make sure the side doors are properly closed.

Use the starter switch key to lock the side doors.

ENGINE HOOD Opening

Closing

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CP99B082

CP99B083

Unlatch the fasteners on the side of the hood and then raise the hood completely until the strut locks automatically in position.

!

Raise the hood slightly to release the strut, the strut tilt the hood downwards and close the fasteners.

NOTE: To lock the hood, lock the lefthand fastener with the starter switch key.

WARNING: Once the hood is completely opened, make sure the locking system is correctly engaged.

!

WARNING: Before undertaking any travel, make sure the hood is properly closed.

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CONTROLS/INSTRUMENTS/ACCESSORIES

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

IMPORTANT: Do not operate machine with the panels removed.

!

the

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

CP99B084

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.

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

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WINDSHIELD WASHER RESERVOIR

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LOWER PANELS

CP99B032

Template Name: OM_1_col Template Date: 1994_04_29

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 11 under “Right-hand control arm”.

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CONTROLS/INSTRUMENTS/ACCESSORIES

LOAD HANDLING EYE Template Name: OM_1_col Template Date: 1994_04_29

1

2 CK99J002

CK99J002

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For machines up to serial number DCH4600138, to handle a load inferior to 12 000 kg (11 765 daN), it is imperative for all slings and chains be attached to the connecting rod eye (1). To handle a load superior to 12 000 kg (11 765 daN), it is imperative for all slings and chains be attached around the connecting rod/ bucket linkage pin (2). See “Load Handling” in the “Operating Instructions” Section.

For machines with serial numbers DCH4600139 and above, 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: 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.

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WARNING: The maximum authorized load which may be lifted with the load handling eye (1) is 12 000 kg (11 765 daN).

Never use this eye to lift loads which are heavier.

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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 or the connecting rod/ bucket linkage pin.

!

WARNING: Never use the connecting rod eye or the connecting rob/bucket linkage pin if the bucket has been removed.

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 or the connecting rod/bucket linkage pin.

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CONTROLS/INSTRUMENTS/ACCESSORIES

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.

CP99B033

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SELECTOR BLOCKS (optional)

1

CD99M008

These blocks, located on the upperstructure at the bottom of the boom, make it possible to select the correct hydraulic circuit for the optional tool to be mounted.

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

IMPORTANT: The machine can be damaged if the optional circuit main relief (1) setting is altered without first consulting a CASE Dealer.

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

IMPORTANT: Consult your CASE Dealer before mounting optional tools.

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Template Name: OM_1_col Template Date: 1994_04_29

CP99B034

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SAFETY VALVE (optional)

CONTROLS/INSTRUMENTS/ACCESSORIES

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

A24690

CS98M633

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

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CP99B034

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

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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CONTROLS/INSTRUMENTS/ACCESSORIES

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

IMPORTANT: This pump is in the front storage box and should be used only for fuel.

STEP 3

1

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

STEP 2

STEP 4

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PDF0361

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.

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FUEL TANK FILLER PUMP

CD99B005

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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Template Name: OM_1_col Template Date: 1994_04_29

Remove the filler cap from the fuel tank.

CONTROLS/INSTRUMENTS/ACCESSORIES STEP 5

STEP 9

Template Name: OM_1_col Template Date: 1994_04_29

CP99B036

CD99B005

Place the delivery hose in the fuel tank.

Put the filler cap back on the fuel tank.

STEP 6

STEP 10

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CD99B006

CD99B006

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

NOTE: The pump has a 10 amp fuse.

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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OPERATING INSTRUCTIONS

121

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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.

- 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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- 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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BEFORE OPERATING THE MACHINE

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

- 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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Template Name: OM_1_col Template Date: 1994_04_29

- Make sure all houds, side doors and lower panels are properly closed.

OPERATING INSTRUCTIONS

MACHINE OPERATION Template Name: OM_1_col Template Date: 1994_04_29

!

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.

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

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- 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.

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- 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.

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

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

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

- 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.

- 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.

Template Name: OM_1_col Template Date: 1994_04_29

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

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OPERATING INSTRUCTIONS

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

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.

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

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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

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

Change the oil in the swing reduction gear. See “Swing reduction gear” in the “Lubrication/Filters/Fluids” Section.

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OPERATING INSTRUCTIONS

STARTING THE ENGINE 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.

Leave the control cancellation lever in raised position.

STEP 2

STEP 4 TRIM THIS EDGE

CK98M009

A23898

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

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

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Template Name: OM_1_col Template Date: 1994_04_29

CK98M014

Leave the left-hand control arm in raised position.

OPERATING INSTRUCTIONS STEP 5

(In cold weather)

Template Name: OM_1_col Template Date: 1994_04_29

CK98M014 CK98M014

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

Turn the starter switch key to “HEAT” position and hold it there until the audible alarm device sounds.

(In cold weather)

IMPORTANT: Never hold the key in heat position for more than 30 seconds.

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CP98N005

In cold weather, the message “Eng. pre heat” appears on the systems display panel. See item 11 under “Systems display panel” in the “Controls/Instruments/ Accessories” Section.

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OPERATING INSTRUCTIONS STEP 6

CP98N005

CK98M014

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.

STEP 9 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.

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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.

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STEP 8

CP98N005

Run the engine until the “Auto warm up” message disappears from the systems display panel.

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 7

OPERATING INSTRUCTIONS STEP 10

STEP 12

Template Name: OM_1_col Template Date: 1994_04_29

CK98M010

CS98M626

Lower the control cancellation lever.

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

STEP 11

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

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A23898

Lower the left-hand control arm.

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OPERATING INSTRUCTIONS

After starting the engine and before using the machine, allow the hydraulic fluid to reach a temperature of 20°C, as indicated by the appearance of the first bar segment on the hydraulic fluid temperature indicator. See item 7 under “Systems display panel” in the “Controls/Instruments/Accessories” Section.

Hydraulic oil warm-up

Once the engine has started, the warming-up process begins automatically. At first, engine speed is held at a pre-determined, low level. As the temperature increases, engine speed increases in proportion. It is possible to interrupt the warming-up process at any time, simply by manually changing engine speed or by operating one of the control levers.

Warming-up takes approximately 5 to 10 minutes.

Engine manual warm-up With the engine throttle button a quarter open, start the engine and allow it to run approximately for 5 to 10 minutes. When the coolant temperature reaches the green zone on the indicator, carry out the hydraulic fluid warm-up procedure.

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 into the green zone on the indicator. See item 7 under “Systems display panel” in the “Controls/Instruments/Accessories” Section.

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

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Engine automatic warmup

Template Name: OM_1_col Template Date: 1994_04_29

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

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BRINGING THE MACHINE UP TO OPERATING TEMPERATURE

OPERATING INSTRUCTIONS

ENGINE OPERATION 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 :

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

- Let the engine run at idle speed 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.

- There are no oil, fuel or water leaks.

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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.

Check the instrument console regularly.

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OPERATING INSTRUCTIONS

OPERATING THE MACHINE IN COLD WEATHER Engine oil

They should be fully charged.

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

Fuel 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.

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

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

OPERATING THE MACHINE IN HOT WEATHER Follow the recommendations made below : 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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Coolant solution

Template Name: OM_1_col Template Date: 1994_04_29

Batteries

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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.

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

On steeply sloping ground, keep engine at maximum speed.

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The following operations are likely to damage the machine. You are therefore advised to avoid them :

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

Never reduce engine speed when traveling down slopes.

Excavation using the weight of the machine as a force of impact.

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.

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

!

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

Template Name: OM_1_col Template Date: 1994_04_29

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.

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.

Avoid turning the machine on steep slopes.

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

3.

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

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 and the left-hand control arm.

7.

Press the control locking switch and the upperstructure swing locking switch to make all machine functions operational once more. See intems 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.

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1.

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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.

IMPORTANT: Before undertaking any travel, raise the attachment.

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.

Traveling in a straight line (in reverse)

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Traveling in a straight line (forwards)

CS98M546

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MACHINE TRAVEL

CS98M547

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

Template Name: OM_1_col Template Date: 1994_04_29

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.

!

WARNING: It is mandatory to remove the counterweight before undertaking any travel without the attachment or transporting the machine without the attachment.

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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 STEP 1

STEP 2 (Machine with attachment)

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CD95M248

Place a block behing the trailer wheels.

Install the trailer side extensions (if fitted).

PDH0248

Place the machine in line with the trailer, with the travel reduction gears towards the access ramps. Raise the attachment and bring it to about twenty centimetres above the bed of the trailer.

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

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OPERATING INSTRUCTIONS STEP 2 (Machine without attachment)

PDH0249

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

STEP 3 (Machine with attachment)

When moving from the ramps onto the trailer bed, raise the boom slightly as soon as the attachment touches the trailer so as to bring the machine level and then move forward until the machine is resting entirely on the trailer.

STEP 5 (Machine with attachment)

Select slow travel speed. Move the machine slowly forward onto the ramps, with the attachment still approximately twenty centimetres above the trailer bed.

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CS99B518

Place the machine in line with the trailer, with the travel reduction gears towards the access ramps.

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STEP 4 (Machine with attachment)

(Machine without attachment)

PDH0250

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

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Template Name: OM_1_col Template Date: 1994_04_29

Select slow travel speed and move the machine slowly forward onto the ramps.

OPERATING INSTRUCTIONS STEP 6 (Machine with attachment)

STEP 7 Lock the upperstructure swing function.

Template Name: OM_1_col Template Date: 1994_04_29

STEP 8 Stop the engine, remove the starter switch key, raise the control cancellation lever and the left-hand control arm.

STEP 9 Make sure that all doors, hoods and access panels are correctly locked.

STEP 10 PDH0251

Bring the machine right to the front of the trailer and lower the attachment onto the trailer bed.

Fold the rear view mirrors inwards.

STEP 11

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STEP 6 (Machine without attachment)

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PDF0360

(Machine with attachment) Use blocks and chains to fasten the machine and the attachment to the trailer.

CS99B519

Bring the machine right to the front of the trailer and swing the upperstructure 180°.

(Machine without attachment) Use blocks and chains to fasten the machine to the trailer.

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OPERATING INSTRUCTIONS

Remove the blocks and fastening chains.

2.

Start the engine.

3.

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

4.

Lower the control cancellation lever and the left-hand control arm.

5.

(Machine with attachment) Raise the attachment to bring it a few centimetres above the trailer bed.

6.

Select low travel speed.

7.

(Machine with attachment) Move forward slowly, raising the attachment so as to keep it a few centimetres off the ground.

8.

(Machine without attachment) Move the machine slowly forward.

9.

Turn the rear view mirrors back to their correct position.

PDH0251

MACHINE READY FOR TRANSPORT

STEP 12 (Machine without attachment)

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1.

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Unloading

STEP 12 (Machine with attachment)

CS99B519

Measure the distance between the ground and the highest point of the machine. You must know the overall height. See “Machine overall dimensions” in the “Specifications” Section.

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Template Name: OM_1_col Template Date: 1994_04_29

MACHINE READY FOR TRANSPORT

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 the load fixing point (eye on the bucket connecting rod or the connecting rod/bucket linkages pin) depending on machine serial number. See “Load handling eye” in the “Controls/Instruments/Accessories” Section and “Maximum loads” in the “Specifications” 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

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

See “Left-hand control arm” (item 12) in the “Controls/Instruments/Accessories” Section.

- Do not exceed, in any circumstances, the limits shown on the load handling chart. See “Maximum loads” in the “Specifications” Section. 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.

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Template Name: OM_1_col Template Date: 1994_04_29

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

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

Template Name: OM_1_col Template Date: 1994_04_29

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

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

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.

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OPERATING INSTRUCTIONS

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.

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

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 :

CS99J510

- of 15% on the hydraulic limit,

The load fixing point is the eye on the bucket connecting rod or the connecting rod/ bucket linkage pin depending on machine serial number. 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.

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- of 33% on stability,

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LOAD HANDLING CHART

Template Name: OM_1_col Template Date: 1994_04_29

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

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OPERATING INSTRUCTIONS

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

CS99B515

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1.

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.

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.

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

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

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OPERATING INSTRUCTIONS

!

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.

Template Name: OM_1_col Template Date: 1994_04_29

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

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OPERATING THE MACHINE ON SLOPING GROUND

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OPERATING INSTRUCTIONS

OPERATING THE BACKHOE BUCKET Filling Template Name: OM_1_col Template Date: 1994_04_29

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

PDH0493M

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PDH0494M

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CORRECT

WRONG

WRONG

The backhoe bucket will dig in and cause a stall.

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

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OPERATING INSTRUCTIONS

!

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

Assembly STEP 1

STEP 4

2

1

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

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1

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QUICK IMPLEMENT INSTALLATION AND REMOVAL (optional)

STEP 2

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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Template Name: OM_1_col Template Date: 1994_04_29

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.

OPERATING INSTRUCTIONS STEP 6

STEP 8

Template Name: OM_1_col Template Date: 1994_04_29

CK99H002

CK99G001

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

STEP 7

Place the switch in the locked position.

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

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

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CS99G514

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

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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OPERATING INSTRUCTIONS

Disassembly

STEP 4

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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STEP 1

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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Template Name: OM_1_col Template Date: 1994_04_29

CK99H001

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

OPERATING INSTRUCTIONS

PARKING THE MACHINE STEP 1

STEP 4

Template Name: OM_1_col Template Date: 1994_04_29

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.

STEP 3 CS98M626

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.

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STEP 5

CS98M626

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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.

CK98M014

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

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OPERATING INSTRUCTIONS

!

WARNING: 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.

STEP 9

CK98M014

Stop the engine and remove the starter switch key.

A23949

Lock the operator’s compartment door and make sure that the hoods, lower panels and side doors are properly fastened.

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

CK98M009

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STEP 7

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STEP 6

Raise the control cancellation lever.

A23898

Raise the left-hand control arm and get out of the operator’s compartment.

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Template Name: OM_1_col Template Date: 1994_04_29

STEP 8

OPERATING INSTRUCTIONS

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

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

!

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.

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.

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CP99B035

Use this hole for towing the machine.

!

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

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OPERATING INSTRUCTIONS

USING OPTIONAL TOOLS (optional) STEP 1

STEP 2

2

1 3

A24690

CS98M635

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4

CS98M636

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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Template Name: OM_1_col Template Date: 1994_04_29

CS98M634

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NOTE: Consult your CASE Dealer before mounting optional tools.

OPERATING INSTRUCTIONS STEP 3

STEP 5

Template Name: OM_1_col Template Date: 1994_04_29

1

CP99B034

CD98N008

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

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IMPORTANT: Never adjust the main relief valve (1) pressure setting without first having contacted your CASE Dealer.

STEP 4

Use the pedal to operate the optional tool.

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

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.

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CP99B040

Place the switch on the left-hand control in the desired position.

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OPERATING INSTRUCTIONS

Your machine can have one of two auxiliary hydraulic circuits. One circuit is for single acting, continuous flow equipment, such as hydraulic breakers. 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 breaker configuration 1

2

4

2

3 CP99B034

CS99B528

CS99B526

1.

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

2.

Place the supply valve (2) on the flow selector (3) in the position shown. The line on the supply valve shows the flow direction.

3.

Make sure that the pressure of the main relief valve (4) has correctly been adjusted by your CASE Dealer to suit the working pressure of the hydraulic breaker.

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1

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AUXILIARY HYDRAULIC CIRCUITS

IMPORTANT: Never change the setting of the main relief valve (4) without first consulting your CASE Dealer.

See “Using optional tools”.

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

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Template Name: OM_1_col Template Date: 1994_04_29

4.

OPERATING INSTRUCTIONS

Concrete crusher configuration Template Name: OM_1_col Template Date: 1994_04_29

1

2

1

4

2

3 CP99B034

CS99B529

CS99B527

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1.

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

2.

Place the supply valve (2) on the flow selector (3) in the position shown. The line of the supply valve shows the flow direction.

3.

Make sure that the pressure of the main relief valve (4) 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 (4) 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

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

CS99C627

NOTE: It is mandatory for the lifting ring (1) to be removed and the ring hole plugged before using the hydraulic breaker.

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.

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1

- 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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HANDLING THE HYDRAULIC BREAKER (optional)

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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Template Name: OM_1_col Template Date: 1994_04_29

Breaking by penetration (or cutting)

OPERATING INSTRUCTIONS

CHOICE OF TOOLS ON A HYDRAULIC BREAKER (optional) 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.

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.

Blunt tool TRIM THIS EDGE

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

- Concrete.

- Breaking boulders.

Compacting plate - 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

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- 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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OPERATING INSTRUCTIONS

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.

Template Name: OM_1_col Template Date: 1994_04_29

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

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SPECIAL CONDITIONS OF USE ON A HYDRAULIC BREAKER (optional)

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127

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. Stop the engine and remove the starter switch key.

4. 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

INTERVALS Template Name: OM_1_col Template Date: 1994_04_29

N B

INTERVALS IN HOURS

O F

P A G E 127

P O I N T S

SERVICE POINTS

C L E A N

R E P L A C E

C H E C K

-

2

-

2

138 127

Tool shank hydraulic breaker (optional) Tool retaining pins hydraulic breaker (optional)

2 -

10

127

-

10

142

Greasing tool hydraulic breaker (optional) Engine oil level

1

10

146 153 167

Coolant level Hydraulic reservoir level Idler wheel and rollers

1 1 -

10 10 10

174 176 127

Radiator and oil cooler Fan/alternator belt Hydraulic breaker (optional)

1 1 -

10 10 50

137 148 148

Quick coupler (optional) Drain fuel tank sediment Drain water separator

1 1

50 50

178 178 171

Fuel tank filter Air tank Track tension

1 1 2

145 135 154

Cooling circuit hoses/clamps Turntable bearing Drain hydraulic reservoir sediment

3 1

163 165 168

Primary air filter element Swing reduction gear oil lever Travel reduction gears oil lever

1 1 2

173 176 201

Pad screw torque (NOTE 3) Fan/alternator belt tension Battery electrolyte level

1 2

136 139 143

Engine pulley Turntable teeth Engine oil (NOTE 1)

2 1 1

143 149 174

Engine oil filter (NOTE 2) Fuel filters Radiator and oil cooler

1 3 1

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Tighten any loose connections hydraulic breaker (optional) Impact hydraulic breaker (optional)

G R E A S E

D R A I N

2

50

50 50 100 200(1) 250 250 250(2)

250 250 250(2) 500 500 500 500 500 500

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250(2) 250 250

SERVICING INTERVALS N B O F

SERVICE POINTS Hydraulic breaker (optional) Attachment Pilot filter (NOTE 2)

19 1

155 155 157

Suction filter Return filter (NOTE 2) Ultra Clean filter

1 1 1

157 162 162

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

1 1 1

165 169 179

Swing reduction gear (NOTE 4) Travel reduction gears (NOTE 4) Rocker arm clearance

1 2 1

179 202 203

Machine inspection and cleaning Alternator Starter motor

1 1 1

146 155 157

Cooling circuit Suction filter Hydraulic oil

1 1 1

77 193 194

Safety valves Fire extinguisher Air conditioning

2 1 1

C H E C K 600(10)

G R E A S E

D R A I N

1000 1000 1000 1000 1000 1000 1000(3) 1000(4) 1000 1000 1000(5) 1000

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

Template Name: OM_1_col Template Date: 1994_04_29

127 134 154

C L E A N

R E P L A C E

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P A G E

P O I N T S

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INTERVALS IN HOURS

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SERVICING INTERVALS (1) Or every 6 months.

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

Template Name: OM_1_col Template Date: 1994_04_29

(3) Or after cleaning 6 times.

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

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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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SERVICING INTERVALS

HYDRAULIC BREAKER INTERVALS (optional) 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.

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.

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

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EVERY 50 HOURS OR AT LEAST ONCE A MONTH

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Maintenance intervals

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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Template Name: OM_1_col Template Date: 1994_04_29

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.

169

LUBRICATION/FILTERS/FLUIDS

FLUIDS AND LUBRICANTS Lubricants must have the correct properties for each application.

Template Name: OM_1_col Template Date: 1994_04_29

!

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 climates -20°C to +40°C Fluid type ISO VG 46

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

Cold climates

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

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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LUBRICATION/FILTERS/FLUIDS

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.

RD97F136

Template Name: OM_1_col Template Date: 1994_04_29

RB97F100

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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.

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Engine oil

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LUBRICATION/FILTERS/FLUIDS

Oil viscosity/Oil range Template Name: OM_1_col Template Date: 1994_04_29

A 3

1

2

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4 B CS98M561

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(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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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.

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.

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

Template Name: OM_1_col Template Date: 1994_04_29

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.

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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.

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LUBRICATION/FILTERS/FLUIDS

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FLUID AND LUBRICANT CAPACITIES AND SPECIFICATIONS Template Name: OM_1_col Template Date: 1994_04_29

ENGINE Type of oil............................................................................... CASE N°1 engine oil Capacity ......................................................................................................34 litres COOLING SYSTEM Cooling system capacity ............................................................................. 60 litres FUEL SYSTEM Reservoir capacity .................................................................................... 650 litres HYDRAULIC SYSTEM Type of fluid.............................................................................CASE hydraulic fluid Total system capacity ................................................................................450 litres Reservoir capacity ................................................................................... 210 litres

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TRAVEL REDUCTION GEARS Type of oil....................................................API GL5 grade 80W90 or ISO VG 150 Capacity (per reduction gear) ....................................................................... 9 litres SWING REDUCTION GEAR Type of oil....................................................API GL5 grade 80W90 or ISO VG 150 Capacity ......................................................................................................18 litres

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Template Name: OM_1_col Template Date: 1994_04_29

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RIGHT PAGE

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LUBRICATION/FILTERS/FLUIDS

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

7

1

3

2 TRIM THIS EDGE

6 8

5

5

4

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CS99B520

NOTE: The figures mentioned in brackets show the number of grease points.

Every 1000 hours

Every 1000 hours

2

1

CP99B085

CP99B086

Boom bottom pin............................(3)

Boom cylinder bottom pin.............. (2)

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LUBRICATION/FILTERS/FLUIDS Every 1000 hours

Every 1000 hours

5

CP99B085

CP99B042

Boom cylinder top pin.................... (2) Dipper cylinder bottom pin............. (1)

Bucket linkages ............................. (6) Every 250 hours

Every 1000 hours

6 TRIM THIS EDGE

4

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3

CP99B041

Dipper/boom linkage ..................... (1) Dipper cylinder top pin .................. (1) Bucket cylinder bottom pin ............ (1)

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Template Name: OM_1_col Template Date: 1994_04_29

Turntable bearing .......................... (3)

CP99B087

LUBRICATION/FILTERS/FLUIDS Every 500 hours

Every 500 hours

7

8

Template Name: OM_1_col Template Date: 1994_04_29

CP99B080

CD99B086

Engine pulley .................................(2)

Turntable teeth.............................. (1) See “Greasing the swing reduction gear”.

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LUBRICATION/FILTERS/FLUIDS

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 NOTE: The figures mentioned in brackets show the number of grease points.

CK97A009

Template Name: OM_1_col Template Date: 1994_04_29

Quick coupler ................................ (1)

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Every 50 hours

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Quick coupler (optional)

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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

1. 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.

- Remove the protective cover from the lower, central area.

- Remove the plate (2) from underneath the machine.

- Discharge the water or cloudy grease.

- Install the plate (2).

- Insert new grease through the port (3) and install the inspection cover (1).

2

3

Template Name: OM_1_col Template Date: 1994_04_29

CS99B521

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4. If the presence of water is detected, remove the plate (2) and drain off the water.

1

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GREASING THE TURNTABLE TEETH

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LUBRICATION/FILTERS/FLUIDS

LEVELS Every 10 hours

Every 10 hours

Template Name: OM_1_col Template Date: 1994_04_29

CP99B088

CP99B045

Engine oil.......................................(1)

Hydraulic reservoir ........................ (1)

Every 10 hours

Every 250 hours

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CP99B044

CP99B089

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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LUBRICATION/FILTERS/FLUIDS Every 250 hours

CP99B046

CP99B090

Batteries ....................................... (2)

Swing reduction gear..................... (1)

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 500 hours (After the first 50 hours of operation) Oil filters replacement ................................................................... Every 500 hours (After the first 50 hours of operation) Oil type ..........................................................................See “Fluids and lubricants” Oil capacity ................................................................................................. 34 litres

Level STEP 1

STEP 3

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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CP99B088

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.

CP99B088

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 NOTE: Change the oil while the engine is still warm. The oil will flow more easily.

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

STEP 2

CP99B091

Remove the drain plugs from the engine and the filters. Allow the oil to drain.

STEP 5

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Fit new seals on the drain plugs and install the drain plugs.

STEP 6

CP99B088

Remove the oil filler cap.

STEP 3

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STEP 4

CP99B053

Clean the areas around the filters and remove them.

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Template Name: OM_1_col Template Date: 1994_04_29

Remove the screws from panel under the engine to gain access to the sump and then place a receptacle of a suitable capacity under the engine.

LUBRICATION/FILTERS/FLUIDS STEP 7

STEP 8

Template Name: OM_1_col Template Date: 1994_04_29

2 2 1 CS99B522

CP99B088

Remove the filter elements (1) and install new elements, after checking the condition of the seals (2) and replacing them if necessary. Install the filter assemblies and tighten the screws to a torque of 6 to 7 daNm.

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IMPORTANT: Excessive tightening can damage the filters and their seals.

Fill the engine with new engine oil (34 litres). Install the oil filler cap.

STEP 9 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: Always wait fifteen minutes to allow the oil to return to the sump before checking the oil level.

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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

Template Name: OM_1_col Template Date: 1994_04_29

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.

Consult your CASE Dealer for suitable coolant solution.

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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 ..........................................................................................60 litres

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Service specifications

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LUBRICATION/FILTERS/FLUIDS

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

CP99B044

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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”.

Open the radiator drain valve.

Draining

NOTE: Have a receptacle of a suitable capacity ready.

STEP 1

STEP 3

CP99B093

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CP99B092

Remove the radiator cap.

CD99B007

Open the drain valve located on the engine block.

NOTE: Have a receptacle of a suitable capacity ready.

STEP 4 Rinse the radiator and the expansion reservoir with clean water.

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LUBRICATION/FILTERS/FLUIDS STEP 5 Close the drain valves when the radiator is completely empty. Fill it again.

Filling STEP 1

CP99B044

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.

Template Name: OM_1_col Template Date: 1994_04_29

IMPORTANT: Do not fill the expansion reservoir above the “FULL” mark.

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STEP 3

CP99B092

Fill with coolant solution via the radiator until overflowing and install the radiator cap.

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STEP 2

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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 filters replacement................................................................. Every 500 hours Fuel tank capacity ..................................................................................... 650 litres Type of fuel ...................................................................See “Fluids and lubricants”

Draining water and sediment from the fuel tank

Draining water from the water separator

A 2 TRIM THIS EDGE

1 CP98N033 CP99B055

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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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LUBRICATION/FILTERS/FLUIDS

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.

CD99B010

Clean the area around the filter heads.

1

Apply a thin coat of oil or grease on the new filter seals.

2

1

NOTE: Do not fill the new filters with fuel before installing.

CD99B010

Install the new filters. Turn the filters until the seals come into contact with the filters heads and turn an extra half turn by hand.

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Place a receptacle of a suitable capacity under the filters and remove the filters, using a filter wrench.

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Replacing the fuel filters

NOTE: If the engine does not regain full power after replacing the filters, bleed the system.

CS99B523

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 filters. Overtightening the filters can damage the seals and filters.

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 and the left-hand control lever, then unlock the machine controls, using the control unlocking switch on the left-hand control arm.

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STEP 4 CK98M014

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

CP98N005

Make sure the control locking indicator lamp goes out on the systems display panel.

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LUBRICATION/FILTERS/FLUIDS STEP 5

A23875

CK98M014

Turn the starter switch key to “OFF” position.

STEP 7

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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

IMPORTANT: As soon as air begins to escape, do not loosen the plug any further.

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Template Name: OM_1_col Template Date: 1994_04_29

CP99B060

Loosen the air pressure release plug on the hydraulic reservoir and release all pressure.

LUBRICATION/FILTERS/FLUIDS

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 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 .................................................................................... 210 litres Total system capacity ................................................................................450 litres Type of oil......................................................................See “Fluids and lubricants”

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NOTE: 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.

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!

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.

!

WARNING: Before carrying out any service work on hydraulic filters or the hydraulic system, remove the hydraulic reservoir breather cap and press the button to release all pressure in the system. Failure to observe these instructions can cause injury. See “Releasing pressure in the hydraulic system”.

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Filling the reservoir

STEP 1

Release all pressure in the hydraulic reservoir. See “Releasing pressure in the hydraulic system”, step 7.

CS98N547

STEP 2

CP99B060

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.

CP99B045

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

Release all pressure in the hydraulic reservoir. See “Releasing pressure in the hydraulic system”, step 7.

Release all pressure in the hydraulic system. See “Releasing pressure in the hydraulic system”.

1 2 3 4 CP99B061

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CP99B059

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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LUBRICATION/FILTERS/FLUIDS

Release all pressure in the hydraulic reservoir. See “Releasing pressure in the hydraulic system”, step 7.

Release all pressure in the hydraulic reservoir. See “Releasing pressure in the hydraulic system”, step 7.

1

2

2

3

1

4

3 5 4 CS99B525

Clean the top of the hydraulic reservoir and clean the suction filter cover.

Remove the cover (1) and O-ring (2) and spring (3) on the top of the suction filter rod assembly.

Remove the suction filter (4) 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 (4), spring (3) 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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CS99B525

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

Ultra clean filter replacement

Close the two valves (8).

Template Name: OM_1_col Template Date: 1994_04_29

Release all pressure in the hydraulic reservoir. See “Releasing pressure in the hydraulic system”, step 7.

Remove the four cover bolts (1) and remove the cover (2), O-ring (3) and spring (4).

Carefully lift the old filter element (6) out of the body (5).

Use a clean cloth and clean out the filter body (5).

Carefully install a new filter element (6) in the body (5), making sure the word “Top” on the new element is facing upwards.

8

Install the spring (4), new O-ring (3) and cover (2).

Open the two valves (8).

CP99B094

Start the engine and run at idle speed.

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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.

8

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CP99B095

7

1

2 4 5

3 6 CI98M236

Clean the top of the filter with solvent.

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LUBRICATION/FILTERS/FLUIDS

Release all pressure in the hydraulic reservoir. See “Releasing pressure in the hydraulic system”, step 7.

CP99B045

Put clean hydraulic fluid on the seal of the new drain filter.

Turn the new filter clockwise to install. Do not over-tighten.

CP99B060

Remove the reservoir cover plate.

Using a pump, remove the fluid from the hydraulic reservoir. Have a container with a suitable capacity ready.

CP99B059

Open the drain valve to remove the remaining fluid from the reservoir.

Replace the suction filter, return filter, pilot filter, drain filter and the Ultra Clean 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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Release all pressure in the hydraulic system. See “Releasing pressure in the hydraulic system”.

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 right-hand side door.

CP99B090

Loosen the fitting on the top of the swing reduction gear to release any air.

Tighten the fitting 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.

CP99B096

Clean the top of the pump and the air bleed plug with solvent and remove the air bleed plug.

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Fill the pump via the upper orifice with new clean hydraulic fluid. As soon as the oil is flush with the orifice, install and tighten the 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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LUBRICATION/FILTERS/FLUIDS

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.

4

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- 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.

3

1

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Replacing the hydraulic fluid and filters when a hydraulic breaker is used (optional)

2 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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LUBRICATION/FILTERS/FLUIDS

Return filter

Template Name: OM_1_col Template Date: 1994_04_29

Release all pressure in the hydraulic reservoir. See “Releasing pressure in the hydraulic system”, step 7.

Remove the four screws (1) on top of the case and remove the cover (2), indicator and O-ring (3) assembly.

Replace the filter (5) with a new filter.

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.

CP99B063

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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.

Remove the drain plug (6) and drain the hydraulic oil.

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LUBRICATION/FILTERS/FLUIDS

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.

Air filter restriction indicator

The hoses should be replaced before they are worn.

Service specifications Inspect and clean the primary element ......................................... Every 250 hours or when the message “Air filter” appears 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: The primary element can be cleaned. The secondary element can not be cleaned and must be replaced.

IMPORTANT: Observe the air filter service intervals shown above. Clean filters mean longer engine life.

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CP98N005

If the message “Air filter” appears on the systems display panel, it is necessary to service the air filter, regardless of when the next service operation is due. See item 11 under “Systems display panel” in the “Controls/Instruments/Accessoires” Section.

Template Name: OM_1_col Template Date: 1994_04_29

Inspection

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AIR FILTER

LUBRICATION/FILTERS/FLUIDS

Removing the elements

STEP 4

STEP 1

Template Name: OM_1_col Template Date: 1994_04_29

CP99B067

Remove the wing nut.

CP99B066

Remove the wing nut and then remove the cover.

STEP 5

STEP 2

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CP99B069

Remove the secondary element if it needs replacing.

CP99B065

Remove the wing nut.

IMPORTANT: The secondary element must be replaced, not cleaned.

STEP 3

CP99B068

Remove the primary element.

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LUBRICATION/FILTERS/FLUIDS

IMPORTANT: Make sure your face is protected before using compressed air.

PDE0088

If the primary element is oily :

PE08311

If the primary element is dry : 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.

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.

Inspecting the primary element

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Clean it in water with a suitable detergent (consult your CASE Dealer). Instructions for using the detergent are printed on the packaging.

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Cleaning the primary element

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

PDE0378

Check the primary element for damage by placing an inspection lamp inside the element.

IMPORTANT: Replace the primary element if light can be seen through a hole, however small.

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Template Name: OM_1_col Template Date: 1994_04_29

IMPORTANT: Compressed air pressure should not exceed 7 bar.

LUBRICATION/FILTERS/FLUIDS

Installing the elements

STEP 3

STEP 1

Template Name: OM_1_col Template Date: 1994_04_29

CP99B064

Install the cover and then install the wing nut.

CP99B067

Install the secondary element and tighten the wing nut.

STEP 4

STEP 2

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CP99B064

Check that the dust ejector under the filter is working correctly.

CP99B065

Install the primary element and tighten the wing nut.

STEP 5 Start and run the engine at low idle and make sure the message on the systems display panel has disappeared.

IMPORTANT: If exhaust smoke is abnormal after cleaning, the air filter primary element must be replaced.

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LUBRICATION/FILTERS/FLUIDS

SWING REDUCTION GEAR Oil level check ............................................................................... Every 250 hours Oil change ................................................................................... Every 1000 hours (after the first 250 hours of operation) Oil capacity..................................................................................................18 litres Oil type ..........................................................................See “Fluids and lubricants”

Level

STEP 3

STEP 1

Install the dipstick

Park the machine on flat, horizontal ground. Stop the engine and remove the starter switch key.

Draining and refilling STEP 1

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Park the machine on flat, horizontal ground. Stop the engine and remove the starter switch key.

STEP 2

STEP 2

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Service specifications

CP99B090

Remove the dipstick and the filler plug.

CP98N043

Remove the dipstick. The oil should come up to the hatched area. Add oil if necessary trhough this orifice.

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Template Name: OM_1_col Template Date: 1994_04_29

CP99B090

LUBRICATION/FILTERS/FLUIDS STEP 3

STEP 6

Template Name: OM_1_col Template Date: 1994_04_29

CP99B090

CP99B090

Place a receptacle of a suitable capacity under the upperstructure and remove the drain plug.

STEP 4

Add oil through the filler hole until the level is correct.

STEP 7 Install the dipstick and the filler plug.

Allow the oil to drain.

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NOTE: The oil takes a relatively long time to drain.

STEP 5 Install the drain plug.

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LUBRICATION/FILTERS/FLUIDS

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) ................................................................... 9 litres Oil type ..........................................................................See “Fluids and lubricants”

Level

STEP 4

STEP 1 Park the machine on flat, horizontal ground.

3

STEP 2

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CP99B089

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Remove the plug (2) and check the oil level. The level must come up to the lower edge of the orifice. If necessary, remove plug (3) and add oil through orifice (3) until the level comes up to the bottom edge of orifice (2).

1

CP99B089

Move the machine so that plug (1) is in the lowest possible position.

STEP 5

STEP 3

Install plugs (2) and (3).

Stop the engine and remove the starter switch key.

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

CP99B089

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

CP99B089

Place a receptacle of a suitable capacity under the travel reduction gear and remove the three plugs.

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CP99B089

Install the plug (1), fill with oil through the orifice (3) until oil 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) 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.

Cleaning

STEP 2

When the machine has been working in mud, a reduction in temperature can cause the mud to solidify.

STEP 1

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CK98M016

Turn the engine throttle button to maximum speed position.

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STEP 3 CS99A841

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.

CD98N008

Use the travel speed selection pedal to select high speed.

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MAINTENANCE/ADJUSTMENTS STEP 4

CS99A841

Repeat Steps 1 to 4 for the other track.

STEP 4

Checking tension

Use the travel control lever to operate the track in reverse for a few moments.

STEP 1 Park the machine on flat, horizontal ground.

STEP 5

STEP 2

Stop the engine and remove the starter switch key.

Clean the tracks.

STEP 6

PE07531

Measure the sag of the track at the center between the base of the undercarriage and the pad.

The value should be between : Steel tracks : 340 mm and 360 mm.

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STEP 5

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.

Template Name: OM_1_col Template Date: 1994_04_29

CD98N008

Operate the travel control lever for the raised track forwards and then in reverse, to remove the mud.

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STEP 3

MAINTENANCE/ADJUSTMENTS STEP 7

STEP 3

Adjust tension if necessary.

Remove the grease gun and clean the grease fitting.

Template Name: OM_1_col Template Date: 1994_04_29

STEP 8

STEP 4

Repeat Steps 3 to 7 for the other track.

Repeat Steps 1 to 3 for the other track.

Adjusting tension This operation is to be carried out after the tension has been checked.

To reduce tension STEP 1

To increase tension STEP 1

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CP99B071

Loosen the grease fitting adaptor about three turns to allow grease to flow out of the cylinder.

CP99B072

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Clean the grease fitting adaptor and connect the grease pump hose to the grease fitting.

!

STEP 2

WARNING: Never unscrew the grease fitting adaptor completely to speed up the flow of grease. The grease in the cylinder is under high pressure.

PE07531

Inject grease to obtain the right amount of track sag.

The value should be between : Steel tracks : 340 mm and 360 mm.

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MAINTENANCE/ADJUSTMENTS

PE07531

As soon as the right track sag is obtained, tighten the adaptor.

The value should be between : Steel tracks : 340 mm and 360 mm.

PE08316

Tighten the pad screws to a torque between 980 and 1180 Nm.

Clean the grease adaptor and fitting.

STEP 4 Repeat Steps 1 to 3 for the other track.

Template Name: OM_1_col Template Date: 1994_04_29

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.

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STEP 3

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Steel pad screw torque

STEP 2

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MAINTENANCE/ADJUSTMENTS

RADIATOR AND OIL COOLER Service specifications Template Name: OM_1_col Template Date: 1994_04_29

Check for leakage .......................................................Every 10 hours or every day Clean............................................................................................. Every 500 hours

Cleaning

STEP 3

STEP 1

6 2

1

5 1

CP99B098

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CP99B098

Remove the screws (1) and remove the intake grille (2).

Remove the safety screws (5). Remove the screws (6) and tilt the oil cooler forward.

STEP 4

STEP 2

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3 4

CP99B099 CP99B098

Remove the wing nuts (3) and then remove the grille (4).

Remove the expansion reservoir assembly.

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MAINTENANCE/ADJUSTMENTS

Clean the radiator and the oil cooler: - Dry dust : use compressed air.

- Mud : clean with a hose.

- Greasy deposits : use perchlorethylene.

NOTE: Make sure the grille (4) is correctly in position in the lower guides.

STEP 8

IMPORTANT: Make sure your face is protected before using compressed air.

2

1

IMPORTANT: The use of trichlorethylene is strictly forbidden.

1

STEP 6

CP99B078

Install the intake grille (2) and mount the screws (1).

6

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STEP 9

5 CP99B098

Install the oil cooler in position and mount the screws (6) and safety screws (5).

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STEP 5

STEP 7

Install the expansion reservoir assembly.

4

CP99B099

Install the grille (4) and the wing nuts (3).

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Template Name: OM_1_col Template Date: 1994_04_29

CP99B099

3

MAINTENANCE/ADJUSTMENTS

FAN AND ALTERNATOR DRIVE BELTS 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

CS99B524

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 belts.

Check carefully to ensure that the belts are correctly positioned in the pulley grooves. If the belts are 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 belts slack, the belts can slip in their housing and cause the engine to overheat or the battery to receive insufficient charge.

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MAINTENANCE/ADJUSTMENTS

1

1 CP98N005

CS99B524

Remove the two mounting bolts (1). Use a lever to push the alternator inwards.

Remove the warn belts.

Install new belts.

Adjust the belt tension.

Tighten the two mounting bolts.

Start the engine and make sure the message on the systems display panel has disappeared.

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If the drive belts break, the message “Alternator” will appear on the systems display panel. Shut down the engine immediately, remove the starter switch key and replace the drive belts. See item 11 under “Systems display panel” in the “Controls/Instruments/Accessories” Section.

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Replacing the drive belts

Template Name: OM_1_col Template Date: 1994_04_29

NOTE: It is imperative to replace both belts at the same time.

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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.

CP99B074

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AIR TANK Service specification Draining water from the air tank ...................................................... Every 50 hours Before starting up the machine, turn the drain tap (1) under the tank 90°, allow the water to drain and then close the tap.

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IMPORTANT: Make sure your face is protected before using compressed air.

1 A27399

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MAINTENANCE/ADJUSTMENTS

ADJUSTING ENGINE ROCKER ARM CLEARANCE Check .......................................................................................... Every 1000 hours NOTE: Have your CASE Dealer check the clearance.

INSPECTING AND CLEANING THE MACHINE Service specifications 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.

Template Name: OM_1_col Template Date: 1994_04_29

Or whenever oil or grease has been spilt on the machine. Clean off with steam or a high pressure water jet.

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Inspect and clean ........................................................................ Every 1000 hours

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Service specification

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MAINTENANCE/ADJUSTMENTS

CHECKING FOR CYLINDER LEAKAGE Template Name: OM_1_col Template Date: 1994_04_29

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.

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.

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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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When cleaning 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.

The use of gasoline, paraffin, paint solvents, etc. will cause discoloration, cracks or deformation of these parts.

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MAINTENANCE/ADJUSTMENTS

REPLACING A TOOTH TIP ON A BACKHOE BUCKET Removal STEP 1

CD99B012

Remove the worn tooth tip.

Installation STEP 1

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CD99B011

Place the bucket a few centimetres above the ground. Stop the engine and remove the starter switch key.

STEP 2

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STEP 3

CD99B013

Remove the locking pin from its housing by striking it with a hammer until it is ejected.

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Template Name: OM_1_col Template Date: 1994_04_29

CD99B012

Clean the mating surface on the adaptor.

MAINTENANCE/ADJUSTMENTS STEP 2

STEP 3

Template Name: OM_1_col Template Date: 1994_04_29

CD99B012

CD99B014

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.

IMPORTANT: Make sure the locking pin is not installed back to front.

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NOTE: When replacing a tooth tip, it is advisable to replace the locking pin at the same time.

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MAINTENANCE/ADJUSTMENTS

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 Start the engine. Move the dipper into its housing. Stop the engine and remove the starter switch key.

STEP 3

STEP 3

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Stop the engine and remove the starter switch key.

CP99B075

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.

STEP 5 Install the connecting rod/bucket linkage pin and the retaining pins and rings.

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Template Name: OM_1_col Template Date: 1994_04_29

CP99B075

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REPLACING A BACKHOE BUCKET

MAINTENANCE/ADJUSTMENTS

Template Name: OM_1_col Template Date: 1994_04_29

STEP 6

STEP 7

Push the seals back into their housings.

Adjust the dipper/bucket shimming. See “Shimming the backhoe bucket”.

STEP 8 Grease the linkages.

SHIMMING THE BACKHOE BUCKET The machine is provided with a bucket adjustment mechanism which eliminates the side play in the bucket-to-arm linkage area caused by wear. This delays the effects of wear and thereby increases the service life of the bushings and pins.

NOTE: If the bucket side play adjustment is not carried out properly, scuffing, unusual noise and side play will occur, causing damage to the O-rings.

Side play adjustment Install the necessary number of shims on the inside of the bucket ear.

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Drive the linkage pin back into position and install the retaining ring and pin.

Install the cap (1) and the screws.

NOTE: When the screws in the cap (1) are tightened, the inner bushing moves towards the dipper and takes up the play.

2

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CP99B076

Check the play between the dipper and the bucket ear If there is a lot of play, remove the screws, the cap (1) and the shims (2).

IMPORTANT: The inner bushing has a lug which prevents it from turning. The cap (1) has an orifice on its inside surface.

When installing the cap (1), make sure the lug is inside this orifice.

Use the shims (2) as a feeler gauge to determine the number of shims necessary to take up the play.

Remove the dipper/bucket linkage pin retaining ring and pin and drive the linkage pin outwards slightly.

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MAINTENANCE/ADJUSTMENTS

Removal

STEP 4

Tools required - A hammer - A bronze or brass drift - A flat-headed screwdriver STEP 1

CP99C007

Drive out the mounting pins with a bronze or brass drift.

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STEP 5

CP99C005

Place the hydraulic breaker laying on hard, flat ground.

STEP 2

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REPLACING A TOOL ON A HYDRAULIC BREAKER (optional)

Stop the engine and remove the starter switch key.

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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Template Name: OM_1_col Template Date: 1994_04_29

STEP 3

MAINTENANCE/ADJUSTMENTS

Template Name: OM_1_col Template Date: 1994_04_29

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

CP99C011

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CP99C009

Check the tool bushing and oil seal for wear and replace them if necessary.

See “Replacing a tool bushing on a hydraulic breaker”.

Install the plugs and retaining pins. Put the rubber plate (if fitted) back at the bottom.

STEP 2

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Clean and coat the tool and mounting pins with grease.

STEP 3

CP99C010

Insert the tool, aligning the grooves on the tool with the mounting pin holes.

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MAINTENANCE/ADJUSTMENTS

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”.

CP99C014

Check the condition of the oil seals and replace them if necessary.

Drive out the mounting pins and plugs.

STEP 3

STEP 2 Lubricate the contact surfaces of the tool bushing and its housing.

Template Name: OM_1_col Template Date: 1994_04_29

CP99C012

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STEP 2

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REPLACING A TOOL BUSHING ON A HYDRAULIC BREAKER (optional)

CP99C013

Remove the tool bushing.

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MAINTENANCE/ADJUSTMENTS STEP 3

Template Name: OM_1_col Template Date: 1994_04_29

CP99C013

Install the tool bushing in its housing and then install the mounting pins and plugs.

STEP 4 Install the tool. See “Replacing a tool on a hydraulic breaker”.

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MAINTENANCE/ADJUSTMENTS

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.

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

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.

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CP99C005

Place the hydraulic breaker laying on hard, flat ground.

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REPLACING A HYDRAULIC BREAKER (optional)

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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Template Name: OM_1_col Template Date: 1994_04_29

STEP 3

MAINTENANCE/ADJUSTMENTS STEP 4

Template Name: OM_1_col Template Date: 1994_04_29

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

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Grease the linkage pins.

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MAINTENANCE/ADJUSTMENTS

WEAR LIMITS ON A HYDRAULIC BREAKER (optional)

3 2 1

CS99C629

The first groove (1) is worn, but the second one (2) is still visible. The tool bushing can still be used. Turn the tool bushing 90 degrees to utilize the surface which has not been worn.

Carry out the same operation for the second groove (2), using the mounting pin groove (3).

The tool bushing must be replaced when both grooves (1) and (2) are worn out.

See “Replacing a tool bushing on a hydraulic breaker”.

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Tool

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Tool bushing

CS99C630

New

Wear limit

CB 4000 ......................................... Ø 140 mm .......................................Ø 138 mm CB 5200 ......................................... Ø 160 mm .......................................Ø 158 mm For replacement, see “Replacing a tool on a hydraulic breaker”.

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Template Name: OM_1_col Template Date: 1994_04_29

Type

MAINTENANCE/ADJUSTMENTS

INSPECTING AND SERVICING THE QUICK COUPLER (optional) Template Name: OM_1_col Template Date: 1994_04_29

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.

If the quick coupler does not operate correctly, check the following :

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- 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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Any modification of the quick coupler without prior authorization can cause serious injury. Do not undertake any modifications without authorization from your CASE Dealer.

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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MAINTENANCE/ADJUSTMENTS

!

WARNING: Any unauthorized modifications made to this machine can cause serious injury. Do not undertake any modifications without first consulting your CASE Dealer.

CS98M573

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FIRE EXTINGUISHER (not supplied)

CP99B027

It is strongly recommended to have a fire extinguisher available and to keep it in the front storage box.

Service specifications 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.

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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 viceversa). Never connect the welding apparatus earth to a component of the hydraulic system.

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WELDING ON THE MACHINE

MAINTENANCE/ADJUSTMENTS

AIR CONDITIONING Service specification Template Name: OM_1_col Template Date: 1994_04_29

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

Electrical wiring problems

Repair

Defective battery

Replace

Defective regulator Defective alternator

See your CASE Dealer

Template Name: OM_1_col Template Date: 1994_04_29

Defective battery charge.

Adjust

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Incorrect belt tension

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PROBLEM

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203

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.

A23902

A23955

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The fuses are located to the right at the rear of the cab.

A notice on the cover gives the function and amperage of each fuse.

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ELECTRICAL SYSTEM

3

13

4

14

5

15

6

16

7

17

8

18 19

9 10

20 CS98N552

(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, radio....................... 10 A Starter switch ................................................................................................... 10 A Air conditioning, heater.................................................................................... 20 A Attachment, upperstructure frame and cab working lights............................. 15 A Not used........................................................................................................... 15 A Not used........................................................................................................... 15 A Not used........................................................................................................... 15 A Windshield wiper/washer................................................................................. 10 A Horn, operator’s compartment light................................................................. 10 A Radio, cigarette lighter..................................................................................... 10 A Computor ......................................................................................................... 15 A Computor ......................................................................................................... 10 A Control locking ................................................................................................. 15 A Control cancellation ......................................................................................... 10 A Not used........................................................................................................... 10 A Rotating beacon............................................................................................... 10 A Fuel filler pump ................................................................................................ 20 A Option solenoid valve ...................................................................................... 15 A Not used........................................................................................................... 10 A Not used........................................................................................................... 10 A Fuse (incorporated in the fuel tank filler pump) .............................................. 10 A

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12

Template Name: OM_1_col Template Date: 1994_04_29

2

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11

1

ELECTRICAL SYSTEM

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

Check electrolyte level .................................................................. Every 250 hours or when over the message “Battery level” appears on the systems display panel 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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CP98N005

CP99B046

If the message “Battery level” appears on the systems display panel, it is necessary to check the electrolyte level in the batteries regardless of when the next service operation is due. See item 11 under “Systems display panel” in the “Controls/ Instruments/Accessories” Section.

Open the left-hand doors.

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ELECTRICAL SYSTEM

CP99B046

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.

Make sure the message has disappeared on the systems display panel.

!

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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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

Remove the cell caps and check the level in each batteries cell. The level should be between 10 and 15 mm above the plates.

Add distilled water if necessary, then install the cell caps.

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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 terminal covers.

2.

Connect the positive (+) cable to the positive (+) terminal on the first machine battery.

3.

Connect the negative (-) cable to the negative (-) terminal on the second machine battery.

4.

Start the engine.

5.

Remove the booster battery negative (-) cable and then the positive (+) cable.

6.

Install the terminal covers.

ALTERNATOR Service specification Check .......................................................................................... Every 1000 hours

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!

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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205

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.

7.

Clean or replace the air filter element.

8.

Drain the cooling system, leave the drain valves open and do not tighten the radiator filler 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, place a “Do not start” label on the right-hand control arm and then raise the control cancellation lever and the left-hand control arm.

13. Lock the hods, the side doors and the cab door.

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LEFT PAGE

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, swing reduction gear, 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.

12. Remove the “Do not operate” tag and start the engine, following the starting up procedure.

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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RIGHT PAGE

Template Name: OM_1_col Template Date: 1994_04_29

11. Unplug the air filter inlet and the exhaust pipe.

220

SPECIFICATIONS

ENGINE Template Name: OM_1_col Template Date: 1994_04_29

Make and type ................................................................ MITSUBISHI 6D24-TCE1 Turbo.................................................................................................................. yes Number of cylinders .............................................................................................. 6 Bore/stroke.................................................................................130 mm x 150 mm Displacement ........................................................................................ 11 945 cm3 Cooling ....................................................................................................... by water Batteries start .............................................................................. 2 12 volt batteries

Working conditions Speed.................................................................................................... 2000 r.p.m.

Power : ECC 1289.......................................................................216 kW (293 hp) Capacity : Engine oil............................................................................................ 34 L Fuel tank...........................................................................................650 L

HYDRAULIC SYSTEM TRIM THIS EDGE

Two variable flow piston-type pumps.

Main pump output ...............................................................................2 x 340 L/mn Safety valve pressure setting Attachment/power boost .................................................................. 320/348 bar Swing ...................................................................................................... 294 bar Travel ...................................................................................................... 320 bar

Control valves

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Four control valve sections for left-hand travel, boom, bucket and dipper acceleration.

Five control valve sections for right-hand travel, auxiliary circuit, dipper, swing and boom acceleration.

Boom/dipper load holding valves.

Auxiliary circuit control valve section.

Swing Fixed flow, piston-type pump.

Single-disk, automatic oil-bath brakes.

Upperstructure swing speed ....................................................................... 8.7 rpm

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SPECIFICATIONS

Three speed hydraulic motors with axial pistons.

Planetary reduction gears.

Low speed.............................................................................................0 to 2.0 kph Medium speed.......................................................................................0 to 2.8 kph High speed ............................................................................................0 to 5.0 kph Gradeability ...................................................................................................... 70% Crowd force (with 3.40 m dipper) ..........................................................24 060 daN Break-out force (with 3.40 m dipper) .....................................................19 570 daN Hydraulic reservoir capacity ........................................................................... 210 L Total hydraulic system capacity...................................................................... 450 L

One-piece frame with welded components.

Lubricated track rollers and idler wheels.

Grease cylinder track tension system.

Steel tracks ........................................................................... 600 mm and 760 mm Ground pressure (with 600 mm pads)........................................................ 0.78 bar Chain guide ........................................................................ in front, centre and rear

SAFETY DEVICES Controls locked by raising control cancellation lever and left-hand control arm.

Horn.

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UNDERCARRIAGE

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Travel

LAMPS/INDICATORS Three travel speeds, hydraulic oil temperature, engine coolant temperature, fuel level, control locking and hydraulic check.

Guaranteed by the manufacturer.

In accordance with European directive 86/662/EEC (as modified).

Inside the operator’s compartment (LpA).............................................. 79 decibels Outside the operator’s compartment (LwA) ........................................ 108 decibels

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Template Name: OM_1_col Template Date: 1994_04_29

NOISE LEVELS

SPECIFICATIONS

WEIGHTS Template Name: OM_1_col Template Date: 1994_04_29

With monobloc boom, 3.40 m dipper, 2000 L backhoe bucket, operator and full fuel tank.

With 600 mm pads ...................................................................................45 400 kg With 760 mm pads ...................................................................................46 200 kg Counterweight .............................................................................................7400 kg Quick coupler ................................................................................................740 kg

MONOBLOC BOOM Length .......................................................................................................... 7.10 m

DIPPER Length .......................................................................... 2.50 m, 3.40 m and 4.00 m

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SPECIFICATIONS

BACKHOE BUCKET

1200 L 1450 L 1700 L 2000 L 2250 L 2500 L 2700 L

Width (mm)

900

1050

1200

1350

1500

1650

1750

Weight (kg)

1204

1332

1422

1511

1638

1728

1773

Heavy duty SAE capacity

2000 L

Quarry 2250 L

2500 L

1350

1500

1650

Weight (kg)

1575

1700

1790

2580 L

Width (mm)

1750

Weight (kg)

2200

Extra-heavy duty SAE capacity

1880 L

Width (mm)

1350

Weight (kg)

1800

Template Name: OM_1_col Template Date: 1994_04_29

Width (mm)

SAE capacity

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SAE capacity

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General purpose

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SPECIFICATIONS

MACHINE OVERALL DIMENSIONS C

Template Name: OM_1_col Template Date: 1994_04_29

G

A F I H D E

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B

M

K

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J L B9408005

With monobloc boom, 2.50 m dipper and bucket (A) ................................................................................................................ 3.56 m (B) ................................................................................................................ 3.26 m (C) ...............................................................................................................11.70 m (D) ................................................................................................................ 6.04 m (E) ................................................................................................................ 2.99 m (F) ................................................................................................................ 1.38 m (G) ................................................................................................................ 3.35 m (H) ................................................................................................................ 5.47 m (I)................................................................................................................. 4.40 m (J) ................................................................................................................. 2.75 m (K) ................................................................................................................ 0.60 m (L) (with 600 mm pads) ................................................................................ 3.43 m (L) (with 760 mm pads) ................................................................................ 3.59 m (M)................................................................................................................ 0.50 m

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SPECIFICATIONS

WORKING RANGE G

F

C

D

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E

H

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A B

2.44 m 2.50 m 3.40 m 4.00 m Dipper Dipper Dipper A (Maximum reach) ............................. 11.20 m ..................11.94 m................ 12.50 m B (Maximum reach at ground level) .... 10.95 m ..................11.71 m................ 12.28 m C (Maximum depth at tooth tips) .......... 6.89 m ....................7.75 m................... 8.39 m D (Maximum depth for 2.44 m long flat-bottomed trench) ................ 6.71 m ....................7.60 m................... 8.26 m E (Maximum dumping heigh) ............... 7.53 m ....................7.78 m................... 7.94 m F (Maximum height)............................. 10.81 m ..................11.06 m.................11.22 m G (Minimum attachment turning radius)................................... 5.23 m ....................5.02 m................... 5.01 m H (Maximum vertical depth).................. 5.54 m ....................6.37 m................... 6.96 m

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Template Name: OM_1_col Template Date: 1994_04_29

B9409105

SPECIFICATIONS

MAXIMUM LOADS Template Name: OM_1_col Template Date: 1994_04_29 TRIM THIS EDGE

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CS99M507

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%.

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SPECIFICATIONS

Distance Balanciers

Godets

3,00 m

4,50 m

6,00 m

7,50 m

4,00 m

1320 kg

13 730* (1)

13 380* (1)

9100

6450

4880

3890

3,40m

1410 kg

20 420* (1)

10 870*

9130

6500

4930

-

2,50 m

1480 kg

15 420* (1)

13 210* (1)

9300

6690

5160

-

Template Name: OM_1_col Template Date: 1994_04_29

IMPORTANT: For machines up to serial number DCH4600138, always attach the load to the connecting rod/bucket linkage pin when the values shown in these charts are followed by a (1). Never use the load handling eye on the bucket connecting rod for loads greater than 12 000 kg (11 765 daN). For machines with serial numbers DCH4600139 and above, use the load handling eye on the bucket connecting rod for all the values given. See “Load handling eye” in the “Controls/Instruments/ Accessories” Section.

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

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9,00 m 10,50 m

213

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SPECIFICATIONS

HYDRAULIC BREAKER (optional) CB 4000 Type Template Name: OM_1_col Template Date: 1994_04_29

Weight (with standard 127 kg tool)..............................................................2320 kg Impact force (CIMA method rating) ...............................................................4191 J Impact rate ....................................................................................... 300 - 560 bpm Operating pressure ............................................................................ 130 - 150 bar Min. relief valve setting ............................................................................... 210 bar Max. relief valve setting .............................................................................. 230 bar Oil flow range .................................................................................. 160 - 230 L/mn Input power ....................................................................................... 58 kW (77 hp) Oil temperature .................................................................................. +40 to +60°C Maximum authorized oil temperature range........................................ -20 to +80°C Noise level (certified by the manufacturer) as per european 86/662/EEC : Without soundproofing .................................................... 85 dB (A) 35 - 50 m With soundproofing ......................................................... 85 dB (A) 22 - 29 m

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Tools

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CS99C633

Type

Length (mm)

Weight (kg)

Diameter (mm)

A = Chisel....................................... 1200........................... 132 ........................ 140 A = Hard rock chisel....................... 1200........................... 132 ........................ 140 A = Soft rock chisel .........................1100........................... 140 ........................ 150 B = Moil point ................................. 1200........................... 127 ........................ 140 C = Blunt tool ................................. 1050........................... 123 ........................ 140 D = Super blunt tool ........................1100........................... 135 ........................ 150 E = Pyramid point........................... 1200........................... 132 ........................ 140

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SPECIFICATIONS

Weight (with standard 206 kg tool)..............................................................3150 kg Impact force (CIMA method rating) ...............................................................5218 J Impact rate ....................................................................................... 300 - 480 bpm Operating pressure ............................................................................ 140 - 150 bar Min. relief valve setting................................................................................ 210 bar Max. relief valve setting............................................................................... 230 bar Oil flow range .................................................................................. 210 - 310 L/mn Input power ..................................................................................... 83 kW (113 hp) Oil temperature .................................................................................. +40 to +60°C Maximum authorized oil temperature range........................................ -20 to +80°C Noise level (certified by the manufacturer) as per european 86/662/EEC : Without soundproofing..................................................... 85 dB (A) 35 - 50 m With soundproofing.......................................................... 85 dB (A) 20 - 30 m

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Tools

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CB 5200 Type

CS99C633

Length (mm)

Weight (kg)

Diameter (mm)

A = Chisel....................................... 1405...........................206 ........................ 160 A = Hard rock chisel ....................... 1405...........................206 ........................ 160 A = Soft rock chisel ........................ 1250...........................197 ........................ 175 B = Moil point ................................. 1405...........................206 ........................ 160 C = Blunt tool.................................. 1255...........................196 ........................ 160 D = Super blunt tool ....................... 1250...........................220 ........................ 175 E = Pyramid point........................... 1405...........................297 ........................ 160

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Template Name: OM_1_col Template Date: 1994_04_29

Type

SPECIFICATIONS

Overall dimensions Template Name: OM_1_col Template Date: 1994_04_29 TRIM THIS EDGE

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CS99C635

Dipper

4.00 m

2.50 m/3.40 m

Type

CB 4000

CB 5200

A

3286

3623

B

2157

2358

C

665

665

D

640

730

E

462

475

F

808.40

808.40

G

231

238

H

319

337

J

Ø 140

Ø 160

NOTE: These values are given in millimeters.

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SPECIFICATIONS

MATERIAL DENSITY/HANDLING TABLE

The figures shown in the table give the maximum density of materials which can be handled, depending on the attachment selected.

NOTE: The densities shown are subject to the following criteria: - For normal pressure settings.

- For 360 upperstructure swing.

- For any position of the attachment.

- For a machine placed on flat. horizontal ground.

The boxes with no figures in this table indicate that the density is higher than 3.

Dippers

Quick coupler

Buckets 1200 L

1450 L

Without

1700 L

2000 L

2250 L

2500 L

2700 L

2.9

2.4

2.1

1.9

1.7

With

3.0

2.5

2.1

1.8

1.6

1.4

Without

2.9

2.4

2.0

1.7

1.5

1.4

2.4

2.0

1.7

1.4

1.2

1.1

2.6

2.2

1.8

1.5

1.3

1.2

2.1

1.7

1.4

1.2

1.1

1.0

3.40 m With

3.0

Without 4.00 m 2.6

Template Name: OM_1_col Template Date: 1994_04_29

With

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2.50 m

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This table enables the most suitable attachment to be selected depending on the density of the materials to be handled. See "Density of various soils and materials".

217

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SPECIFICATIONS

t/m3

%

Loading factor

Template Name: OM_1_col Template Date: 1994_04_29

Clay

Average bank density

Banking-up

DENSITY OF VARIOUS SOILS AND MATERIALS Average swell density

t/m3

Dry

1.48

40

0.72

1.10

Wet

2.10

40

0.72

1.65 1.40

Natural

1.90

40

0.72

With dry gravel

1.65

40

0.72

1.20

With damp gravel

1.85

40

0.72

1.65

Dry

1.50

20

0.83

1.25

Mud

Sand Loose material

Damp

1.95

20

0.83

1.60

Dry

1.75

12

0.89

1.60

Moist

1.90

14

0.88

1.70

Damp

2.10

14

0.88

1.85

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Mold, loam

1.70

33

0.75

1.20

Dry

1.65

25

0.80

1.30

Earth

Damp

1.75

25

0.80

1.40

Wet

1.90

20

0.83

1.60

Sand and gravel

1.85

18

0.85

1.60

Damp clay

2.10

10

0.90

1.90

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Compacted, dry

2.30

25

0.80

1.85

Dry, mold

0.85

40

0.72

0.60

Peat Damp Basalt

1.10

20

0.83

0.90

2.90

50

0.66

1.95

Hard

2.60

65

0.60

1.60

Soft

2.20

50

0.66

1.50

Chalk, calcareous stone

Limestone

1.55

40

0.72

1.10

Diorite-gabro

2.90

50

0.66

1.95

Granite

Rocky materials 2.75

65

0.60

1.70

Dry

1.90

12

0.89

1.75

Damp

2.25

15

0.87

1.95

Gravel

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SPECIFICATIONS

%

2.70

75

Gneiss

Average swell density

t/m3 0.57

1.55

Hard

2.55

60

0.63

1.60

Soft

2.35

54

0.65

1.55

Gypsum

2.35

50

0.67

1.60

Marble

2.75

Marl

Damp Porphyry

40

0.72

1.75

65

0.60

1.70

Conglomerate

2.70

55

0.65

1.75

Schist

2.65

55

0.65

1.75

Silex

2.60

50

0.67

1.75

Trap-Rock

2.70

65

0.60

1.65

Compact

2.50

40

0.72

1.80

Soft

2.30

45

0.67

1.55

Decomposed

2.10

35

0.74

1.55

50% Rock 50% Earth

2.20

33

0.75

1.65

Anthracite

1.35

30

0.78

1.05

Bauxite

1.90

35

0.74

1.40

Caliche

1.25

40

0.72

Rocks

Ash Charcoal

0.25

Through coal

Coal and minerals

0.90 0.65

1.15

25

0.80

2.25

35

0.74

1.70

Hematite

4.50

80

0.55

2.50

Taconite

2.80

40

0.72

1.95

Slag

3.05

70

0.59

Cast concrete

2.60

Beet

0.6/1.2

Coke (fine)

0.90 0.50

Copper (mineral) Iron Clinker

1.55

Bitumen

1.25

Portland cement

1.50

Misc Debris (demolition)

1.60

Lime mortar

1.85

Snow

0.55

Salt

2.00

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1.80

Template Name: OM_1_col Template Date: 1994_04_29

Rocky materials (continued)

2.40 2.75

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Grit

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t/m3

Loading factor

Average bank density

Banking-up

Densitiy of various soils and materials (continued)

SPECIFICATIONS

t/m3

%

Mahogany-birch

Wood

0.70

Acacia-Beech

0.80

Chestnut-Plane

0.65

White oak-lime

0.60

Holm oak

0.98

Ash

0.85

Walnut (green)

0.90

Walnut (dry)

0.65

Poplar

0.40

Fir

0.45

Cork

0.24

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Loading factor

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Average bank density

Banking-up

Densitiy of various soils and materials (continued)

Average swell density

t/m3

C

Adjusting engine rocker arm clearance ....................................179 Air conditioning..........................70, 194 Air conditioning control......................45 Air filter ............................................161 Air tank ............................................178 Alternator.........................................202 Ashtray ..............................................58 Attachment cushion control switch ............................................41 Audible warning device cut-out button ............................................39 Auxiliary attachment control switch ............................................47 Auxiliary control switch......................53 Auxiliary controls ...............................41 Auxiliary hydraulic circuits ...............117

Control arm tilt adjustment lever ....... 39 Control cancellation lever ................. 54 Control locking indicator lamp........... 48 Control locking switch ....................... 45 Cooling system ............................... 145

Backhoe bucket...............................209 Batteries ..........................................200 Before operating the machine ...........81 Boom and bucket right-hand control lever ..................................55 Boom priority switch ..........................47 Breaking techniques........................119 Brightness control button ..................50 Bringing the machine up to operating temperature...............89 C Cab door ...........................................34 Cab door sliding window ...................59 Cab light ............................................58 Checking for cylinder leakage .........180 Choice of tools on a hydraulic breaker........................................120 Cigarette lighter .................................58 Clock .................................................49 Clock hour adjustment ......................53 Clock minute adjustment ...................53 Coat hanger hook..............................58 Connecting booster batteries ..........202 Control arm tilt adjustment and function cancellation lever......47

Decals ............................................... 26 Density of various soils and materials .............................. 218 Dipper ............................................. 208 Dipper and upperstructure swing left-hand control lever......... 55 E Emergency hammer ......................... 59 Emergency shut down switch ........... 45 Engine..................................... 142, 206 Engine automatic return to idle speed selector.................... 43 Engine coolant temperature indicator ........................................ 49 Engine hood...................................... 74 Engine idle speed selector................ 43 Engine operation............................... 90 Engine throttle button........................ 39 Engine troubleshooting ................... 195 Environment.................................... 131 F Fan and alternator drive belts ......... 176 Fire extinguisher ............................. 193 Fluid and lubricant capacities and specifications ....................... 132 Fluids and lubricants ....................... 128 Front storage box.............................. 73 Fuel level indicator ............................ 49 Fuel system .................................... 148 Fuel tank ........................................... 72 Fuel tank filler pump ......................... 79 Fuel tank filter ................................. 178 Fuses .............................................. 198

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B

D

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A

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ALPHABETICAL INDEX

ALPHABETICAL INDEX

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G

N

Grease points.................................. 134 Greasing the hydraulic breaker....... 138 Greasing the turntable teeth ........... 139

Noise levels .............................. 11, 207 O

Hand signals ..................................... 30 Handling the hydraulic breaker ....... 119 Handling the machine ..................... 102 Heating and ventilation ..................... 67 Heating and ventilation controls........ 68 Horn .................................................. 47 Horn volume level switch .................. 41 Hourmeter ................................. 45, 123 Hydraulic breaker intervals ............. 127 Hydraulic fluid temperature indicator ........................................ 49 Hydraulic system..................... 152, 206

Official documents .............................. 7 Operating the backhoe bucket........ 108 Operating the machine in cold weather ................................. 91 Operating the machine in hot weather .................................. 91 Operating the machine in water...... 106 Operating the machine on sloping ground ........................................ 107 Operator’s compartment controls ..... 36 Operator’s seat ................................. 61 Option pedal ..................................... 56 Optional tool supply valves............... 78 Overload indicator switch ................. 47

I

P

Inspecting and cleaning the machine ................................ 179 Inspecting and servicing the quick coupler ........................ 192 Intervals .......................................... 124

Parking the machine....................... 112 Plastic and resin parts .................... 180 Power up switch ............................... 43

H

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L Lamps/indicators............................. 207 Left-hand control arm........................ 44 Levels.............................................. 140 Load handling ................................. 103 Load handling chart ........................ 105 Load handling eye............................. 76 Location of controls and associated components ......... 36 Lower panels..................................... 75 M Machine components........................ 12 Machine operation ...................... 82, 93 Machine overall dimensions............ 210 Machine travel................................... 95 Material density/handling table ....... 217 Maximum loads............................... 212 Message display screen ................... 50 Monobloc boom .............................. 208

Q Quick coupler locking/ unlocking control .......................... 57 Quick coupler locking/ unlocking control switch ............... 47 Quick implement installation and removal ...................................... 109 R Radiator and oil cooler.................... 174 Radio compartment .......................... 41 Rear view mirror ............................... 72 Releasing pressure in the hydraulic system............... 150 Replacing a backhoe bucket .......... 183 Replacing a hydraulic breaker ........ 189 Replacing a tool bushing on a hydraulic breaker................ 187 Replacing a tool on a hydraulic breaker................ 185 Replacing a tooth tip on a backhoe bucket .................. 181

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U

Right, left, front and rear of the machine ................................8 Right-hand control arm......................38 Right-hand control arm rear controls ..................................53 Roof hatch.........................................59 Rotating beacon ................................41 Run-in period.....................................84

Undercarriage ................................. 207 Upperstructure swing locking indicator lamp ................... 48 Upperstructure swing locking switch ............................... 45 Using optional tools ........................ 115 V Ventilation control ............................. 45

Safety devices.................................207 Safety instructions.............................14 Safety valve.......................................77 Selector blocks..................................77 Servicing instructions ......................122 Shimming the backhoe bucket ........184 Side doors .........................................73 Special conditions of use on a hydraulic breaker ................121 Starter motor ...................................203 Starter switch ....................................39 Starting the engine ............................85 Steps and access handles ................35 Stopping the engine ..........................92 Storage tray.......................................59 Storing the machine ........................204 Sun shield .........................................60 Swing reduction gear ......................165 Systems display panel ......................48

W Warning symbol ................................ 50 Wear limits on a hydraulic breaker ....................................... 191 Weights ........................................... 208 Welding on the machine ................. 193 Windshield ........................................ 64 Windshield washer reservoir............. 75 Windshield washer switch................. 41 Windshield wiper switch.................... 41 Working light switch .......................... 43 Working mode indicator .................... 49 Working mode selector ..................... 39 Working range ................................ 211

T To the owner .......................................6 Towing the machine ........................114 Track rollers and idler wheels .........167 Tracks .............................................170 Transporting the machine .................98 Travel control levers and pedals .......56 Travel reduction gears ....................168 Travel speed indicator lamps ............48 Travel speed selector pedal ..............57 Type, serial number and year of manufacture ..............................10

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R

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ALPHABETICAL INDEX

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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.

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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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Printed in France

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