Case CX130B Tier 3 Crawler Excavators Operator's Manual 47452366 - PDF DOWNLOAD

CX130B Tier 3 Crawler Excavator

OPERATOR’S MANUAL

Part number 47452366 4th edition English November 2012 Replaces part number 84543087

CX130B EXCAVATOR OPERATOR’S MANUAL

Part Number: 47452366

CASE TECHNICAL MANUALS Manuals are available from your Dealer for the operation, service, and repair of your machine. For prompt convenient service, contact your Dealer for assistance in obtaining the manuals for your machine.

Your Dealer can expedite your order for Operator’s Manuals, Parts Catalogs, Service Manuals, and Maintenance records.

Always give the Machine Name, Model, and P.I.N. (Product Identification Number) or S.N. (Serial Number) of your machine so your Dealer can provide the correct manuals for your machine.

NOTE: CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any obligation to install them on units previously sold.

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 DEATH OR SERIOUS INJURY M171D

Safety Decals on this machine use the words Danger, Warning, or Caution, which are defined as follows: ●

DANGER: Indicates a hazardous situation that, if not avoided, will result in death or serious injury. The color associated with Danger is RED.

●

WARNING: Indicates a hazardous situation that, if not avoided, could result in death or serious injury.

The color associated with Warning is ORANGE.

●

CAUTION: Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury. The color associated with Caution is YELLOW.

If Safety Decals on this machine are ISO two panel Pictorial, decals are defined as follows: ●

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

and

STOP

if used, are RED.

IMPROPER OPERATION OF THIS MACHINE CAN CAUSE DEATH OR SERIOUS INJURY. 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 practices 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 Corporation instructions on machine operation and maintenance.

WARNING_01_NA

CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Battery post, terminals and related accessories contain lead and lead compounds.

Wash hands after handling.

TABLE OF CONTENTS CHAPTER 1 GENERAL INFORMATION To The Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Identification Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 CHAPTER 2 SAFETY AND DECALS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Utility Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Safety Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Starting and Stopping Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Seat Belt Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 CHAPTER 3 INSTRUMENTS AND CONTROLS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Cab Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Steps and Access Handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 operator’s compartment controls and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Function Cancellation Lever and Safety Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Anti-theft Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Automatic Temperature Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Travel Control Levers and Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Cab Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 CHAPTER 4 OPERATING INSTRUCTIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Run-in Period Of A New Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Before Operating The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Checking Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Machine Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Transporting The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Machine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 CHAPTER 5 LUBRICATION, FILTERS, AND FLUIDS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 General Safety Before You Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Fluids And Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Lubrication And Maintenance Quick Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Machine and Attachment Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

I

CHAPTER 6 MAINTENANCE AND ADJUSTMENTS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Cab Protection (FOPS/ROPS- Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Cab Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Hardware Torque Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19 CHAPTER 7 ELECTRICAL Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Fuses And Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 CHAPTER 8 SPECIFICATIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 CHAPTER 9 INDEX

II

CHAPTER 1 - GENERAL INFORMATION

Chapter 1 GENERAL INFORMATION TO THE OWNER

Figure 1

CT07K021

CX130B HYDRAULIC EXCAVATOR

Your machine has been designed and built to the highest standards of quality. It conforms to all current safety regulations. However, the risk of accidents can never be completely excluded. That is why it is essential to observe elementary safety rules and precautions.

Read this manual carefully, paying particular attention to the instructions concerning safety, operation and maintenance to avoid the risk of injury while operating or servicing the machine.

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

The standard attachments and equipment available for use with this machine are intended for general earth moving purposes, material handling, etc. If the machine is to be used for handling loads, (tubing, concrete pipe sections, shoring material, etc.), make sure the machine is suitably equipped for this type of work.

Do not use this machine for any application or purpose other than those described in this manual. If the machine is to be used for work involving the use of special attachments, accessories or equipment, consult your CASE Dealer in order to make sure that any adaptations or modifications made are in keeping with the machine’s technical specifications and with prevailing safety requirements. Strictly adhere to all legal requirements.

Any modification or adaptation which is not approved by the manufacturer may invalidate the machine’s initial conformity with safety requirements and warranty.

ATTENTION: The engine and fuel system on your machine is designed and built to government emission standards. Tampering by dealers, customers, operators, and end users is strictly prohibited by law. Failure to comply could result in government fines, rework charges, invalid warranty, legal action, and possible confiscation of the machine until rework to the original condition is completed. Engine service and/or repairs must be done by a certified technician only!

1-1

CHAPTER 1 - GENERAL INFORMATION 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. All persons who will be operating this machine shall possess a valid local vehicle operating permit and/or other applicable local age work permit.

The information in this manual is provided on the basis of information that was available at the time the manual was written. Settings, procedures, part numbers, software and other items can change. These changes can affect the service that is given to the machine. Ensure that you have complete and current information from you dealer before you start any machine operation.

Always keep this manual in the operator's compartment (in the seat back, behind the operator's seat). Make sure it is complete and in good condition. If you wish to obtain additional copies, or copies in languages other than that of the country of use, consult your authorized dealer.

NOTICE: The machine must undergo regular inspections, the frequency of which varies according to the type of use. Consult your CASE Dealer.

Before permitting a new operator on this machine, make sure:

• That the operator has received the necessary training on how to operate the machine correctly and safely.

• That the operator has the necessary permits and licenses to operate this machine.

• That the operator has read and understands the instructions given in this manual.

ELECTROMAGNETIC COMPATIBILITY (EMC) Interference may arise as a result of add-on equipment which may not necessarily meet the required standards. As such interference can result in serious malfunction of the unit and/or create unsafe situations, you must observe the following:

• The maximum power of emission equipment (radio, telephones, etc.) must not exceed the limits imposed by the national authorities of the country where you use the machine.

• The electromagnetic field generated by the add-on system should not exceed 24V/m at any time and at any location in the proximity of electronic components.

• The add-on equipment must not interfere with the functioning of the on board electronics. Failure to comply with these rules will render the warranty null and void.

1-2

CHAPTER 1 - GENERAL INFORMATION

RIGHT, LEFT, FRONT, AND REAR OF THE MACHINE The illustration below shows the machine in normal TRAVEL position. In normal TRAVEL position, the cab is over the idler. The travel reduction gears are at the rear of the upper structure.

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.

6

1

4

6

3

5

5

2 Figure 2

CS99A820

1. FRONT 2. REAR

3. RIGHT-HAND SIDE 4. LEFT-HAND SIDE

5. TRAVEL REDUCTION GEARS 6. IDLER

1-3

CHAPTER 1 - GENERAL INFORMATION

IDENTIFICATION NUMBERS Write your machine model number, Product Identification Number (P.I.N.) and serial numbers on the lines provided below. If needed, give these numbers to your dealer when you need parts or information for your machine.

Make a record of the numbers. Keep the record and your Manufacturer’s Statement of Origin in a safe place. If the machine is stolen, report the numbers to your local law enforcement agency.

Machine ➤ Machine Model and Type

➤ Product Identification Number: P.I.N.

➤ Year of Build

Component Serial Numbers ➤ Engine Serial Number

➤ Transmission and Serial Number

➤ ROPS Cab or Canopy Serial Number

➤ Attachment Serial Number

➤

(1) Type/model (2) Serial number RCPH11EXC001AAH

1-4

CHAPTER 1 - GENERAL INFORMATION

MACHINE COMPONENTS

BD02H141

Figure 3

1. Bucket

9. Cab

17. Turn table bearing

2. Bucket link

10. Swing unit

18. Track shoe

3. Arm link

11. Fuel tank

19. Travel unit

4. Bucket cylinder

12. Hydraulic oil tank

20. Lower roller

5. Arm

13. Air cleaner

21. Upper roller

6. Arm cylinder

14. Battery

22. Track tension unit

7. Boom

15. Engine and radiator

23. Take up roller

8. Boom cylinder

16. Counterweight 1-5

CHAPTER 1 - GENERAL INFORMATION

NOTES

1-6

CHAPTER 2 - SAFETY AND DECALS

Chapter 2 SAFETY AND DECALS TABLE OF CONTENTS SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 UTILITY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 PERSONAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 SAFETY AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Proper Entry And Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-6 2-6 2-6 2-7

STARTING AND STOPPING PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Fuel Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Burn Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Hazardous Chemical Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Transporting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Parking The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Ductile Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 SEAT BELT PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Specific Precautions To This Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Cab Interior Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Exterior Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Raise Load Vertically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Lower Load Vertically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Move Load In Horizontally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Move Load Out Horizontally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Raise Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Lower Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Swing Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Swing Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Arm In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Arm Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Counter Rotate Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Counter Rotate Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 Travel Forward. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 Travel Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 Close Bucket (Bucket In Or Dig) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 Open Bucket (Bucket Out Or Dump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 Turn Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 Turn Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 Move This Much . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 Move Slowly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 Stop Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

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CHAPTER 2 - SAFETY AND DECALS

2-2

CHAPTER 2 - SAFETY AND DECALS

SAFETY RULES WARNING 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 death or serious injury.

M171C

Most accidents involving machine operation and maintenance can be avoided by following basic safety rules and precautions. Read and understand all the safety messages in this manual, the safety manual, and the safety decals on the machine before you operate or service the machine. See your dealer if you have any questions.

READ THIS MANUAL COMPLETELY and make sure you understand the controls. All equipment has a limit. Make sure you understand the speed, stopping, steering, stability and load characteristics of this machine before you start to operate.

Do not remove this manual or the safety manual from the machine. See your dealer for additional manuals.

The safety information given in this manual does not replace safety codes, insurance needs, or federal, state, and local laws. Make sure your machine has the correct equipment according to these rules or laws.

CT06M020

Figure 1

OPERATOR’S MANUAL LOCATION AND STORAGE

NOTICE: Safety messages in this section point out situations which can be encountered during the normal operation and maintenance of your machine.

These safety messages also give possible ways of dealing with these conditions.

NOTICE: Additional safety messages are used in the text of the manual to show specific safety hazards.

The safety information contained in this publication does not replace safety codes, insurance needs, federal, state, or local laws. Make certain that your machine has the correct equipment according to these rules or laws.

2-3

CHAPTER 2 - SAFETY AND DECALS

UTILITY SAFETY Safety precautions MUST be followed when working near buried utility lines.

.

During operation it is likely that you will be working around or near buried utility lines which may include, but are not limited to:

• • • •

Electrical Power Line Gas Line Water Line Communication Television

Line

-

Telephone

or

Cable

B e fo r e b e g i n n i n g any t re n ch i n g , o r o t h er construction work it is your responsibility to be aware of all such utility lines buried in the area of your project and to avoid them.

ALWAYS have all local utility companies mark the location of their lines.

In U.S.A. and Canada call one of many One Call System Directory services. If you do not know the local number, call the national number (U.S.A. and Canada only): 1-888-258-0808.

Check with local authorities for laws, regulations and/or strict penalties requiring you to locate and avoid existing utilities.

RH99G001

Figure 2

CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU PERFORM ANY MACHINE OPERATION

Know the utility color code (U.S.A. and Canada): Electric. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red Gas, Oil, or Petroleum . . . . . . . . . . . . . . . . . . . Yellow Communication, Telephone, Television . . . . . Orange Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blue Sewer . . . . . . . . . . . . . . . . . . . . . . . . . .Green/Brown Proposed Excavation. . . . . . . . . . . . . . . . . . . . .White Surveying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pink Reclaimed Water and Slurry . . . . . . . . . . . . . . Purple After locating the utility lines, carefully dig a hole by hand and/or automatic vacuum equipment to the utility line to verify the location and depth of the line.

2-4

CHAPTER 2 - SAFETY AND DECALS

PERSONAL SAFETY ISO two panel pictorial symbol decals are defined as follows:

• • • •

The first panel indicates the nature of the hazard.

The second panel indicates the appropriate method in order to avoid the hazard.

Background color is YELLOW. Prohibition symbols such as

and

STOP

if used are RED.

SAFETY AREA The safety area is the space necessary for the machine to operate at the maximum range of the tool and a full 360° swing plus 6 feet (2 meters).

1

2 CS97M019

Figure 3

1. WORKING AREA 2. SAFETY AREA

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CHAPTER 2 - SAFETY AND DECALS

MACHINE OPERATION • Check all controls in a clear area and make sure the machine is operating correctly.

• Do not permit other persons to ride on the machine. Other persons can fall or can cause an accident.

• Dust, fog, smoke, etc., can decrease your vision and cause an accident. Stop the machine or decrease the speed until you can see everything around you in the work area.

PERSONAL SAFETY

• Be prepared for emergencies. Always have a first aid kit and a working fire extinguisher with you and know how to use each.

• Avoid loose fitting clothing, loose or uncovered long hair, jewelry and loose personal articles.

• Know and use the protective equipment that is to

• Contact with high voltage lines, underground

cables, etc., can cause serious injury or death from electrocution.

be worn when operating this machine. Hard hats, protective glasses, protective shoes, gloves, reflector type vests, respirators and ear protection are examples of types of equipment that may be required.

• Before you drive or operate in an area with high

• Certain protective equipment should be replaced

voltage power lines or cables, tell the power or utility company what you are going to do. You MUST HAVE THE POWER DISCONNECTED OR KEEP A SAFE WORKING DISTANCE from the lines or cables. You must know the safe working distance from the high voltage power equipment and must know any federal, state/provincial or local safety codes or regulations that apply to the job site.

• Electrical cables, gas pipes, water pipes, sewers, or other underground objects can cause injury or death. Learn the location of underground hazards before you operate your machine in a new area.

• When the machine is traveling forward or backward an alarm will sound.

• Inspect the seat belt mounting bolts on a daily

and renewed upon age and wear. Old hard hats may not afford the proper protection required.

Faded and soiled vests are no longer as highly visible as their original intent. See the manufacturer’s recommendation.

• Know and use the hand signals required for particular jobs and know responsibility for signaling.

who

has

the

GENERAL

• It is the responsibility of the operator to read and

understand the Operator’s Manual and other information provided and use the correct operating procedure. Machines should be operated only by qualified operators.

• Do not operate this machine or perform

• Operate the machine controls from the operator’s

maintenance work if you have not had appropriate training and have read and fully understand the instructions and warnings in this manual.

• If this machine rolls over, you can be injured or

• Do not permit riders on the machine.

• Make sure that all protective guards, canopies,

basis to insure their integrity.

seat only. Always fasten the seat belt and keep it securely fastened when operating the machine. killed. You must make a judgment if weather, road, or earth conditions will permit safe operation on a hill, ramp, or rough ground.

• Stay away from hazardous areas such as ditches,

overhangs, etc. Walk around the work area before you start and look for hazards.

• Be alert and always know the location of all

workers in your area. Keep all other persons completely away from your machine. Injury or death can result if you do not follow these instructions.

2-6

doors, etc. are in place and secure.

• Remove all loose objects stored in the machine.

Remove all objects which do not belong in or on the machine and its equipment.

• Do not use the machine as a manlift.

CHAPTER 2 - SAFETY AND DECALS PROPER ENTRY AND EXIT

• Use the recommended hand holds and steps with

at least three points of support when getting on and off the machine. Keep steps and platform clean.

• Do not jump off the machine.

• Do not dismount while the machine is in motion.

• Foreign material or grease on the steps and hand holds can cause an accident. Keep the steps and hand holds clean.

STARTING AND STOPPING PRECAUTIONS • Walk around the machine and warn all personnel

• Remove the starter key when leaving the machine parked or unattended.

OPERATING PRECAUTIONS

• Check steering and other machine control devices

in accordance with the manufacturer’s instructions prior to starting operation. Observe all gauges or warning instruments for proper operation. Operate all controls to insure proper operation. If any malfunctions are found, remove the starter key or disconnect switch key. Place a Do Not Operate tag on the machine until the malfunction is corrected.

• If a failure that causes loss of control such as

who may be servicing the machine or are in the machine path prior to starting. Do not start until all personnel are clearly away from the machine.

Sound the horn before starting.

steering, service brakes or engine occurs, stop the machine motion as quickly as possible, remove the starter key or disconnect switch key.

Place a Do Not Operate tag on the machine, and keep it securely parked until the malfunction is corrected or the machine can be safely moved.

• Walk around the machine’s tool, attachment, or

• Understand the machine limitations and keep the

furthermost contact point to view operation danger area from the work site personnel view and angle. This is the safety area necessary for the machine to operate at the maximum range of the tool plus 6 feet (2 meters).

• Check that the parking device is applied, place the ground drive controls in neutral and check that the auxiliary controls or switches are in neutral or off positions.

• Adjust, secure and latch the seat and fasten the seat belt before starting the machine.

• Start and operate the machine only from the operator’s station.

• Do not bypass the machine’s interlock system.

The interlock system must be repaired if it malfunctions.

• Use battery

booster cables only in the recommended manner. Improper use can result in battery explosion or unexpected machine motion.

Ventilate the battery area before using jumper cables. Make sure that using battery booster cables will not interfere with or harm electronic processing or computer devices.

• Do not operate the engine in an enclosed area without adequate ventilation.

• Park the machine on level ground whenever

possible and apply the parking brake. On grades, park the machine with the track securely blocked.

• Before leaving the operator’s station, lower the

machine under control.

• Operate and drive the machine with care and at

speed compatible with conditions. Use extra caution when operating over rough ground, on slopes, and when turning.

• Note and avoid all hazards and obstructions such

as ditches, underground lines, trees, cliffs, overhead electrical wires or areas where there is danger of a slide.

• Carry loads in recommended positions for maximum stability.

• Never lift loads in excess of capacity.

• Use the recommended machine ballast and counterweighting.

• Know and understand the job site traffic flow

patterns, and obey signalmen, road signs and flagmen.

• Know and understand that job site conditions may

change on an hourly basis. Hills of dirt, debris or obstructions may grow and change from the time you began the day. It is your responsibility to monitor the changes, and keep the machine, tools and attachments, etc. a safe distance.

• Watch for bystanders, and never allow anyone to be under or to reach through the machine and its equipment while operating.

• Select a gear that will prevent excessive speed when going downhill. Do not coast downhill.

equipment to the ground, shut off the engine and place the function cancellation lever into the locked position.

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CHAPTER 2 - SAFETY AND DECALS

• Use proper transport devices when roading the

machine. Proper marking (reflectors, slow moving vehicle emblem, etc.) lights, flashers, signals and beacons may be required. Follow local, state and federal regulations.

• Use the approved attachment point when using the machine for towing. If a cable or chain is used, keep people away from the tow line.

• Before you operate at night, check that all lamps illuminate.

• Make sure that all windows are clean and that the windshield wipers work correctly.

• Engine exhaust fumes can cause death. If you operate this machine in an enclosed area, make sure there is ventilation to replace the exhaust fumes with fresh air.

• Check all controls in a clear area and make sure the machine is operating correctly.

• Dust, fog, smoke, etc., can decrease your vision and cause an accident. Stop the machine or decrease the speed until you can see.

• Contact

with high voltage power lines, underground cables, etc., can cause serious injury or death from electrocution.

• Before you drive or operate in an area with high

voltage lines, cables, or a power station, tell the power or utility company what you are going to do.

You MUST HAVE THE POWER DISCONNECTED OR KEEP A SAFE WORKING DISTANCE from the lines, cables, or power station. Keep all parts of the machine a safe distance away from the power source. You must also know any federal, state/provincial, or local safety codes or regulations that apply to the job site.

If a part of the machine touches high voltage power:

1. Warn other workers NOT TO TOUCH THE MACHINE and to stay away from the machine.

2. If you can break contact, reverse the operation that caused contact with the high voltage power, and move the machine away from the danger area. If you cannot break contact stay in the machine until the utility company de-energizes the line and tells you that the power is off.

3. If you have extreme conditions, such as a fire, etc., and you are forced to leave the machine, do not step off the machine. Jump as far from the machine as possible with your feet together and do not touch the ground with your hands.

2-8

• Do not operate the machine if you do not feel well.

This can be dangerous for you and for the people around you.

• You must make a judgment if weather, road, or

earth conditions will permit safe operation on a hill, ramp, or rough ground.

• Stay away from hazardous areas such as ditches, overhangs, etc. Walk around the work area before you start and look for hazards.

• Be alert and always know the location of all

workers in your area. Keep all other persons completely away from your machine. Injury or death can result if you do not follow these instructions.

• Develop fluid and smooth operating techniques

and maintain the surface condition where the machine travels in order to control vibration transfer to the operator.

CHAPTER 2 - SAFETY AND DECALS MAINTENANCE PRECAUTIONS

• Do not attempt repairs unless trained. Refer to manuals and experienced repair personnel for help.

• Before you service the machine, put a Do Not

Operate tag on the key switch. Make sure that the machine is clearly “tagged out”. A Do Not Operate tag is included in this machine’s Operator Manual packet.

• Wear protective glasses and other required safety

equipment when servicing or repairing the machine.

• Wear gloves to protect hands when handling cable.

• Disconnect the battery before working on the electrical system. Know the consequences of disconnecting any electronic or computer devices.

• Avoid lubrication or mechanical adjustments with

the machine in motion or the engine operating. If the engine must be in operation to make certain adjustments, place the transmission in neutral, apply the parking device, place the equipment in a safe position, securely block the tracks and use extreme caution.

• Securely block the machine or any component that

may fall before working on the machine or component. If possible, use a back up or secondary blocking device, also.

• To prevent unexpected movement, securely block

working elements when repairing or changing working tool parts such as cutting edges.

• Never make repairs on pressurized components, fluid, gas or mechanical until the pressure has been relieved according to the manufacturer’s instructions.

• Whenever servicing or replacing hardened pins,

etc., use a brass drift or other suitable material between the hammer and pin. Alternative: Use a brass hammer, drift or suitable material on the pin, etc.

• Keep the brakes and steering systems in good operating condition.

• Replace all missing, illegible or damaged safety signs/decals. Keep all safety signs/decals clean.

FUEL HANDLING PRECAUTIONS

• Do not smoke or permit open flames while fueling or near fueling operations.

• Never remove the fuel cap or refuel gasoline

engine powered machines with the engine running or hot. Never allow fuel to spill on hot machine components. Never allow fuel to spill on the environment.

• To avoid spilling fuel, maintain control of the fuel filler nozzle when filling the tank.

• Do not fill the fuel tank completely to the top. Allow room for expansion.

• Clean up spilled fuel immediately, and dispose of contaminated material in an environmentally correct manner.

• Tighten the fuel tank cap securely. Should the fuel

cap be lost, replace it only with the original manufacturer’s approved cap. Use of a non-approved cap without proper venting may result in pressurization of the tank.

• Never use fuel for cleaning purposes.

• Use the correct fuel grade for the operating season.

• Use extreme caution when removing radiator

caps, drain plugs, grease fittings or pressure taps.

Park the machine and let it cool down before opening a pressurized tank.

• Release all pressure before working on systems which have an accumulator.

• Use a piece of cardboard, newspaper, or wood to

check for pressurized leaks to prevent fluid penetrating the skin. Pressurize accumulators with the proper gas according to manufacturer’s recommendations.

• Towing this machine is not recommended.

• Observe the proper maintenance procedures.

2-9

CHAPTER 2 - SAFETY AND DECALS HAZARDOUS CHEMICAL PRECAUTIONS

BURN PREVENTION

• If you are exposed to or come in contact with

WARNING Battery acid causes burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing.

hazardous chemicals you can be seriously injured. The fluids, lubricants, paints, adhesives, coolants, etc. used with your machine can be hazardous.

Antidote (external): Flush with water.

Antidote (eyes): Flush with water for 15 minutes and seek medical attention immediately.

Antidote (internal): Drink large quantities of water or milk. Do not induce vomiting. Seek medical attention immediately.

• Material Safety Data Sheets (MSDS) provide

Failure to comply could result in death or serious injury.

• Before you service the machine, check the MSDS

W0111A

WARNING Hazard to bystanders!

Always store batteries in a safe location. Keep out of reach of children and other unauthorized persons.

Failure to comply could result in death or serious injury.

W0224A

for each fluid, lubricant, etc., used in your machine. This information indicates what the risks are and how to service the machine safely.

• Before you service this machine and before you

dispose of the old fluids and lubricants, always be environmentally responsible. DO NOT put oil or fluids on the ground or into containers that can leak. Check with your local environmental or recycling center or your dealer for correct disposal information.

TRANSPORTING PRECAUTIONS

WARNING Explosive gas!

Batteries emit explosive hydrogen gas and other fumes while charging. Ventilate the charging area.

Keep the battery away from sparks, open flames, and other ignition sources. Never charge a frozen battery.

Failure to comply could result in death or serious injury.

W0005A

• When the battery electrolyte is frozen, the battery

can explode, if you try to charge the battery, or you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured.

• Hot coolant can spray out if the radiator cap is

removed. To remove the radiator cap, let the cooling system cool, turn to the first notch, wait until the pressure is released, then remove the radiator cap.

2-10

information about the chemical substances within a product, safe handling procedures, first aid measures and procedures to be taken when the product is accidentally spilled or released. MSDS information is available from your dealer.

• Know the rules, laws, and safety equipment that

may be necessary for transporting this machine on a road or highway.

FIRE EXTINGUISHER It is recommended that a fire extinguisher be maintained on the machine when it is in operation to aid in event of a fire. Be sure that the extinguisher is properly maintained and be familiar with its proper use. See your local authorized dealer for further information.

CHAPTER 2 - SAFETY AND DECALS PARKING THE MACHINE 1. When the work day is finished, make sure the machine is parked on level ground.

IMPORTANT: If you must temporarily park the machine on a hillside, put the front of the machine toward the bottom of the hill. Make sure the machine is behind an object that will not move.

DUCTILE IRON

• Before you weld, cut or drill holes in a part on this

machine, make sure the part is not cast ductile iron. See your dealer if you do not know if a part is cast ductile iron.

2. Lower the attached equipment to the ground.

3. Shift the direction controls to NEUTRAL. 4. Apply the parking brake.

5. Run the engine for a few minutes with no load.

This decreases the temperature of the engine parts evenly.

6. Make sure the engine is at its lowest idle.

7. Turn the key switch to OFF to stop the engine.

8. Always face the machine and use the hand holds when leaving the machine. Do not rush and do not jump from the machine.

9. When you park the machine, make sure the track system is clean. In cold weather or for long storage periods, place the machine on planks.

This will prevent the tracks from freezing to the ground.

If your machine is frozen to the ground, do not try to drive the machine. This will cause damage to the power train.

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CHAPTER 2 - SAFETY AND DECALS

SEAT BELT PRECAUTIONS SPECIFIC PRECAUTIONS TO THIS MACHINE

• Keep the load or tool as low as possible while moving the machine around the job site.

2

• The transport position is to be used only when

transporting the machine. The upper structure should be aligned with the tracks during transport.

Track idlers should be to the front and travel reduction gears to the rear.

1

3

Figure 4

BD02M045

1. RIGHT BELT STRAP 2. LATCH MECHANISM 3. RELEASE BUTTON

1. To latch the seat belt, pull the right belt strap from the retractor.

2. Insert the metal end into the latch mechanism on the left side of the seat.

3. To unlatch the seat belt, press the red button on the left side latch mechanism.

4. The seat belt will automatically retract.

WARNING Avoid injury!

Before starting the engine, securely fasten the seat belt. The seat belt can help ensure your safety if it is properly used and maintained. Never wear a seat belt loosely or with slack in the belt system. Never wear the belt if it is twisted or pinched between the seat structures.

Failure to comply could result in death or serious injury.

W0142A

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CHAPTER 2 - SAFETY AND DECALS

DECALS Safety decals are placed on your machine as a guide for your safety. Walk around the machine, and note the content and location of these decals before operating your machine.

An illegible or missing decal can have far-reaching consequences. Inspect decals daily. Clean and replace damaged decals as necessary.

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.

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

NOTE: This chapter only covers decals relating to safety and machine operation and servicing. For information on all decals for the machine, consult your authorized dealer.

Figure 5

384270A1A

This symbol instructs you to refer the Operator’s M a n u a l fo r f u r t h e r i n f o r m a t i o n r e g a r d i n g maintenance, operational guidelines, etc.

BC00G075

Figure 6

This symbol instructs you to refer to the Service Manual. If you doubt your ability to perform service operations, contact your authorized dealer.

NOTE: Safety Decals on this machine use the words Danger, Warning, or Caution, which are defined as follows:

• DANGER: Indicates a hazardous situation that, if not avoided, will result in death or serious injury. The color associated with Danger is RED.

• WARNING: Indicates a hazardous situation that, if not avoided, could result in death or serious injury. The color associated with Warning is ORANGE.

• CAUTION: Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury. The color associated with Caution is YELLOW.

If Safety Decals on this machine are ISO two panel Pictorial, decals are defined as follows:

• • • •

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

and

STOP

if used are RED.

2-13

CHAPTER 2 - SAFETY AND DECALS CAB INTERIOR DECALS

5

6

1

8 7 4

2

3

DECALSINT

2-14

Figure 7

CHAPTER 2 - SAFETY AND DECALS

1

Figure 8

WARNING1

Decal Number: KHP12142 This decal is located inside the cab on the right window. This decal advises:

• • • • •

to engage the function cancellation lever when leaving the cab for any reason control function interchanges electrocution hazard reading the operator’s manual attachment interference with cab

3

2

KHP11600

Figure 9

KHP12170

Figure 10

Decal Number: KHP11600-00

Decal Number: KHP12170-00

This decal is located on the back glass inside the operator’s compartment. It illustrates the operator procedure for an emergency exit.

This decal cautions the operator to lock the front window after removing or replacing to insure it will remain in a safe position. It is located above the front windshield.

2-15

CHAPTER 2 - SAFETY AND DECALS

6

4

24V

KHP11590-00

CT06K010

Figure 11

Decal Number: KHP11590-00 The decal indicates the voltage rating of the lighter socket. Do not use equipment of any other voltage.

The decal is located on the right front console.

KMP10920

Figure 13

Decal Number: KHP10920-00 The decal indicates the lift capacities of the excavator with several ar m length configurations. It also cautions against exceeding the lift capacities.

5

KHP11590

Figure 12

Decal Number: KHP1316-00 This decal is located on the right side window glass in the Operator’s compartment. It cautions against striking the blade and boom against the dozer blade, if equipped.

2-16

CHAPTER 2 - SAFETY AND DECALS

7

8

KPH1587

Figure 15

Decal Number: KHP1587-00 Located on the r ight side window glass in the operator’s compartment, this decal indicates the machine is equipped with a control pattern selector.

KHP12300

Figure 14

Decal Number: KHP11380-00 The decal is located on the right side window glass in the operator’s compartment. The control pattern decal indicates the pattern of the controller. Make cer tain the actual pattern and the decal in the machine match.

2-17

CHAPTER 2 - SAFETY AND DECALS EXTERIOR DECALS

14

10 11 13

9 23

17 16

15

12 20

19

18

21 22

EXTERIOR

2-18

Figure 16

CHAPTER 2 - SAFETY AND DECALS

9

KHP1014

10

Figure 17

RAP0144

Figure 18

Decal Number: KHP1014-00

Decal Number: KHP0144-00

A high pressure grease warning is located on the track adjustment area.

Located on the rear upper structure of the machine, this decal warns of upper structure swing.

2-19

CHAPTER 2 - SAFETY AND DECALS

11

12

Figure 21

KHP1533 KHP1636

Figure 19

Decal Number: KHP1536-00 Located in the battery compar tment, this decal advises using safe battery procedures and being aware of explosive danger.

Decal Number: KHP1533-00 Inside the engine compartment, this decal warns of the hazard associated with rotating par ts and components.

14 13

BS00M13

Figure 203

Decal Number: KHP1587-00 Located on the right front of the upper structure, this decals warns against coming in contact with power lines.

KHP1534

Figure 22

Decal Number: KHP1534-00 Located inside the engine compartment, the decal warns against fluids under high pressure.

2-20

CHAPTER 2 - SAFETY AND DECALS

15

KHP1542

17

Figure 23

KPH1535

Figure 25

Decal Number: KHP1542-00

Decal Number: KHP1535-00

This decal cautions about high pressure hydraulic fluids and relieving pressure for safety. Use caution w h e n r e m ov i n g t h e hy d r a u l i c t a n k c a p. S e e “Releasing pressure” in the hydraulic system. The decal is located near the hydraulic tank cap.

This decal warns against touching the exhaust system while the engine is running or immediately after the engine stops.

18 16

KPH1011

Figure 26

Decal Number: KHP1011-00 KPH11681

Figure 24

Decal Number: KHP11681-00 This decal instr ucts the operator to use recommended diesel fuel only. It is located near the fill port of the fuel tank.

This decal warns the operator of slippery surfaces.

The decal is located on the rear upper structure.

2-21

CHAPTER 2 - SAFETY AND DECALS

19

KPH1010

21

Figure 27

Decal Number: KHP1010-00 Instructs operator to lock engine hood in place when opening. It is located inside the engine compartment near the holding strut.

KPH10713

Figure 29

Decal Number: KHP1013-00 This decal cautions against starting the machine from anywhere other than the operator’s seat to prevent unexpected articulation. It is located on the upper structure.

20

22

KPH12210

Figure 28

Decal Number: KHP12210-00 This decal warns against standing or climbing on the rear of the machine. It is located on the rear upper structure.

KPH0700

Figure 30

Decal Number: KHP0700-00 This decal states the importance of using correct booster/jumper battery procedures. It is located in the battery compartment.

2-22

CHAPTER 2 - SAFETY AND DECALS

23

KPH10351

Figure 31

Decal Number: KHP10351-00 This is an informational decal stating maintenance intervals and locations. It is located on the inside cover of the tool box (right front of machine).

2-23

CHAPTER 2 - SAFETY AND DECALS

HAND SIGNALS IMPORTANT: When operating the machine, never attempt to carry out tasks calling for the 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.

MOVE LOAD IN HORIZONTALLY

The following is a compilation of the Hand Signals to be used when a flagman is required for Excavator Operation. All personnel associated with the operation of the excavator should know these signals and their meaning before attempting to operate this machine.

RAISE LOAD VERTICALLY

DC04E040

Figure 34

Face Machine Operator, extend right arm toward operator with hand facing operator and move hand in direction of movement required.

MOVE LOAD OUT HORIZONTALLY

DC04E038

Figure 32

Face Machine Operator, raise right forearm vertical, with index finger pointing up and move hand in a small circular motion.

LOWER LOAD VERTICALLY

DC04E041

Figure 35

Face Machine Operator, extend right arm toward operator with back of hand facing operator and move hand in direction of movement required.

RAISE BOOM

DC04E039

Figure 33

Face Machine Operator, extend right arm down, point index finger down and move hand in small circular motion.

DC04E042

Figure 36

Face Machine Operator, extend right ar m out horizontally from shoulder, make a fist with thumb up.

2-24

CHAPTER 2 - SAFETY AND DECALS ARM IN

LOWER BOOM

DC04E043

Figure 37

DC04E046

Figure 40

Face Machine Operator, extend right ar m out horizontally from shoulder, make a fist with thumb down.

Face Machine Operator, bend at elbows with arms facing operator, make fists and point thumbs in toward each other.

SWING LEFT

ARM OUT

DC04E044

Figure 38

DC04E047

Figure 41

Face Machine Operator, extend right ar m out horizontally from shoulder, make a fist with index finger pointing in swing direction.

Face Machine Operator, bend at elbows with arms facing operator, make fists and point thumbs out away from each other.

SWING RIGHT

COUNTER ROTATE LEFT

DC04E045

Figure 39

Fac e M ac hi ne O pe rato r, ext en d le ft a r m ou t horizontally from shoulder, make a fist with index finger pointing in swing direction.

DC04E048

Figure 42

Face machine Operator, place right hand on top of hard hat, bend left arm at elbow to the right, make a fist with left hand with index finger pointing out and rotate hand in a reverse circular motion.

2-25

CHAPTER 2 - SAFETY AND DECALS CLOSE BUCKET (BUCKET IN OR DIG)

COUNTER ROTATE RIGHT

DC04E049

Figure 43

DC04E052

Figure 46

Face Machine Operator, place left hand on top of hard hat, bend right arm at elbow to the left, make a fist with right hand with index finger pointing out and rotate hand in a forward circular motion.

Face Machine Operator, hold left hand in, closed and stationary, hold right hand in, make a fist with index finger pointing toward left hand and move right hand in a small forward circular motion.

TRAVEL FORWARD.

OPEN BUCKET (BUCKET OUT OR DUMP)

DC04E050

Figure 44

Face Machine Operator, bend both elbows in, make fists and rotate fists one over the other in a reverse circular motion TRAVEL REVERSE

DC04E051

Figure 47

Face Machine Operator, hold left hand in, open and stationary, hold right hand in, make fist with index finger pointing toward left hand and move right hand in small forward circular motion.

TURN LEFT

Figure 45

Face Machine Operator, bend both elbows in, make fists and rotate fists one over the other in a forward circular motion.

2-26

DC04E053

DC04E054

Figure 48

Face Machine Operator, raise right forearm up, make fist with right hand and hold stationary, bend left arm in, make fist with left hand and rotate left fist in a small reverse circular motion.

CHAPTER 2 - SAFETY AND DECALS STOP

TURN RIGHT

DE04E055

Figure 49

DC04E058

Figure 52

Face Machine Operator, raise left forearm up, make fist with left hand and hold stationary, bend right hand arm in, make fist with right hand and rotate right fist in a small forward circular motion.

Fa c e M a c h i n e O p e r a t o r, r a i s e l e f t a r m o u t horizontally from shoulder with hand open and facing down, move arm in a horizontal motion back and forth.

MOVE THIS MUCH

EMERGENCY STOP

DC04E056

Figure 50

Face Machine Operator, raise both forearms up, hands open and facing each other, move hands in laterally indicating how far to go.

MOVE SLOWLY

DC04E059

Figure 53

Face Machine Operator, raise both ar ms out horizontally from shoulders with hands open and facing down, move arms in a horizontal motion back and forth.

STOP ENGINE

DC04E057

Figure 51

Fa c e M a c h i n e O p e r a t o r, r a i s e l e f t a r m o u t horizontally toward right shoulder with hand open and facing down, point right index finger up toward open left hand and rotate right hand in a reverse circular motion. (Raise Load Slowly is illustrated).

DC04E060

Figure 54

Face Machine Operator, right arm at side, draw left thumb or index finger across throat.

2-27

CHAPTER 2 - SAFETY AND DECALS

2-28

CHAPTER 3 - INSTRUMENTS AND CONTROLS

Chapter 3 INSTRUMENTS AND CONTROLS TABLE OF CONTENTS CAB DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 STEPS AND ACCESS HANDLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 OPERATOR’S COMPARTMENT CONTROLS AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Operator's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Suspension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Forward and Backward Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Seat Position Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Seat Back Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Lumbar Support Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Seat And Control Arm Assembly Fore And Aft Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Armrest Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Headrest Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 FUNCTION CANCELLATION LEVER AND SAFETY BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Right Hand Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Right Hand Control Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Right Front Console Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Left Hand Control Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Function And Message Display Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Message Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 CONTROL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 ANTI-THEFT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 AUTOMATIC TEMPERATURE CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Flow Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Windshield Defroster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Climate Control Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-22 3-23 3-23 3-23 3-23 3-24 3-24 3-25

TRAVEL CONTROL LEVERS AND PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 CAB FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Side Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Left-hand Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hose Burst Check Valve (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Towing Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load Lifting Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Tank Filling Pump (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-33 3-35 3-36 3-36 3-36 3-38 3-39 3-40 3-40 3-42

3-1

CHAPTER 3 - INSTRUMENTS AND CONTROLS

3-2

CHAPTER 3 - INSTRUMENTS AND CONTROLS

CAB DOORS

3

1 Figure 1

CT06K017

Figure 3

CT06K019

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

WARNING Avoid injury!

Do not leave the door ajar. Secure it in a latched position.

Failure to comply could result in death or serious injury.

2

CT06K017

Figure 2

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

NOTICE: Use the starter switch key to lock and unlock the door.

3-3

CHAPTER 3 - INSTRUMENTS AND CONTROLS

STEPS AND ACCESS HANDLES

2

2

2

2 1

CT06K022

1

Figure 4

CT06K022

To get on or off of the machine use the steps (1) and hand holds (2). There are steps and hand holds located on both sides of the machine.

WARNING Fall hazard!

Jumping on or off the machine could cause an injury. Always face the machine, use the handrails and steps, and get on or off slowly. Maintain a three-point contact to avoid falling: both hands on the handrails and one foot on the step, or one hand on the handrail and both feet on the steps.

Failure to comply could result in death or serious injury.

W0141A

WARNING Fall hazard!

In order to enter or exit the cab, the upper structure frame must be in line with the undercarriage.

Failure to comply could result in death or serious injury.

W0225A

WARNING Fall hazard!

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

Failure to comply could result in death or serious injury.

W0139A

3-4

CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATOR’S COMPARTMENT CONTROLS AND ACCESSORIES WARNING Avoid injury and accidents!

Before starting the engine, make sure that you are fully aware of the location and the function of each control.

Failure to comply could result in death or serious injury.

1

11

14

13 12 10 15

17 7 9

8

16

3

2

4

7 6

5

CT07K016

1 1.

2.

3.

4.

5.

6.

7.

8.

9.

Operator's seat LH control arm Function cancellation lever Safety bar Arm and upper structure swing left-hand control Footrest or option pedal Travel control levers and pedals Footrest or option pedal Front RH console

10.

11.

12.

13.

14.

15.

16.

RH control arm Boom and bucket right-hand control lever Right-hand control arm tilt adjustment lever RH console Air vents Storage compartment Left-hand control arm tilt adjustment and function cancellation lever 17. Dozer blade control lever (if equipped)

3-5

CHAPTER 3 - INSTRUMENTS AND CONTROLS OPERATOR'S SEAT 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.

8

7 9 4 3 5 1 6

2 Figure 5

BD00J066

FORWARD AND BACKWARD ADJUSTMENTS

SUSPENSION ADJUSTMENT

2 1

CD00F010

Figure 6

Turn the dial (1) counter clockwise to obtain softer suspension. Turn the dial (1) clockwise to obtain harder suspension

3-6

CD00F010

Figure 7

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

CHAPTER 3 - INSTRUMENTS AND CONTROLS LUMBAR SUPPORT ADJUSTMENT

SEAT POSITION ADJUSTMENT

3

5 Figure 8

CD00F010

Figure 10

CD00E030

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.

Use the inflation bulb (5) to inflate the lumbar support. Press the button on the tip of the inflation bulb (5) to deflate the lumbar support.

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.

SEAT AND CONTROL ARM ASSEMBLY FORE AND AFT ADJUSTMENT

SEAT BACK ANGLE ADJUSTMENT

6

4

Figure 11

CD00F010

Figure 9

CD00F010

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

WARNING Equipment failure could cause accident or injury!

Always fasten the seat belt securly before you operate the machine. Inspect seat belt parts for wear and damage. Replace any and all worn or damaged parts of the seat belt prior to operation.

Failure to comply could result in death or serious injury.

Pull the lever (6) upwards, and slide the seat and control arm assembly to the desired position, then release the lever.

WARNING Unexpected machine movement!

Before tilting the back of the seat forward, you must raise the armrests. This prevents accidental operation of the control levers.

Failure to comply could result in death or serious injury.

W0210A

W0046C

3-7

CHAPTER 3 - INSTRUMENTS AND CONTROLS

WARNING Avoid injury!

Only make adjustments to the seat when the operator is in the seat and the engine is off. Do not attempt to adjust seat when machine is moving or engine is on.

Failure to comply could result in death or serious injury.

1

2

9

3

8

7

5

4

6 Figure 12

CT06M007

OPTIONAL AIR RIDE SEAT

1. Head rest adjustment 2. Seat belt 3. Lumbar support adjustment 4. Weight adjustment indicator 5. Combination height and weight adjustment

6. Forward and backward seat and control arm adjustment 7. Seat back angle adjustment 8. Forward/backward adjustment 9. Arm rest angle adjustment (one each side)

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

3-8

CHAPTER 3 - INSTRUMENTS AND CONTROLS

1 2

CT06K046

4

Figure 13

Figure 15

CT06M008

COMBINED HEIGHT AND WEIGHT ADJUSTMENT

SEAT BACK ANGLE ADJUSTMENT

Lower the handle (1) to decrease the rigidity of the suspension. Raise the lever to firm suspension. The indicator (2) must be green when the operator is sitting in the seat in order to make these adjustments.

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

WARNING Unexpected machine movement!

Before tilting the back of the seat forward, you must raise the armrests. This prevents accidental operation of the control levers.

Failure to comply could result in death or serious injury.

3

W0210A

CT06K046

Figure 14

FORWARD/BACKWARD ADJUSTMENT Hold the control (3) in the raised position, slide the seat to the required position and release the control.

5

CT06K046

Figure 16

LUMBAR SUPPORT ADJUSTMENT Use the inflation bulb (5) to inflate the lumbar support. Press the button on the tip of the bulb to deflate the lumbar support.

3-9

CHAPTER 3 - INSTRUMENTS AND CONTROLS HEADREST ADJUSTMENT

8

6

Figure 17

CT06M008

SEAT AND CONTROL ARM ASSEMBLY FORWARD AND BACKWARD ADJUSTMENT Pull the control (6) upward and slide the seat and control arm assembly to the desired position, then release the control.

Figure 19

CD00E031

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

To make the headrest return to its rear position, tilt it completely forward and then release it.

SEAT BELT

ARMREST ANGLE ADJUSTMENT

1 2 3

7 CD00E031

Figure 20

CT06K048

Figure 18

Raise the front part of the armrest and adjust to the desired angle using the knob (7), then lower the armrest.

1. RIGHT BELT STRAP 2. LATCH MECHANISM 3. RELEASE BUTTON

1. To latch the seat belt, pull the right belt strap from the retractor.

2. Insert the metal end into the latch mechanism on the left side of the seat.

3. To unlatch the seat belt, press the red button on the left side latch mechanism.

4. The seat belt will automatically retract.

WARNING Avoid injury!

Before starting the engine, securely fasten the seat belt. The seat belt can help ensure your safety if it is properly used and maintained. Never wear a seat belt loosely or with slack in the belt system. Never wear the belt if it is twisted or pinched between the seat structures. Failure to comply could result in death or serious injury.

W0142A

3-10

CHAPTER 3 - INSTRUMENTS AND CONTROLS

FUNCTION CANCELLATION LEVER AND SAFETY BAR

2 2 1

1 CT06K029

Figure 21

Figure 22

CD00E006

The safety bar (1) is designed to discourage the operator from leaving the operator’s compartment without first having lowered the bar.

To make the attachment, travel, and swing functions operational, push the lever (2) forward and the safety bar (1) will come out of the control arm.

The lever (2) operates the safety bar (1) and cancels the functioning of the control levers and pedals.

When the lever (2) is in the raised position, the safety bar (1) is in the retracted position in the control arm and the attachment, travel and swing functions will not operate.

NOTICE: It is also possible to cancel all controls by completely raising the left-hand control arm. See “Left-hand Control Lever”.

WARNING Unexpected machine movement!

Before leaving the operator's compartment, the function cancellation lever must be in the central position and the safety bar must be in the inward position.

Failure to comply could result in death or serious injury.

W0223A

3-11

CHAPTER 3 - INSTRUMENTS AND CONTROLS RIGHT HAND CONSOLE

5

3 1

2

4 6

7

Figure 23

CT06K22

1. MONITOR PANEL T he mo nit or p ane l dis pl ays mac hi ne s ys tem conditions and will check each monitored system when the engine is turned on.

2. TRAVEL MODE SWITCH Use this switch to change the travel mode. When the switch is pressed, the travel speed will toggle between high and low speed. When high speed is selected, a lighted indicator to the upper left of the switch will illuminate. When the machine is in low speed, the indicator light will be out. Each time the engine is started, the travel mode is automatically set in low speed.

3. HORN VOLUME SWITCH Pressing the horn volume selector switch will allow the sound of the horn to be changed from normal to low volume. When low volume is selected a green indicator light will illuminate to the upper left of the switch. The selected horn volume will be retained after the starter switch has been turned off.

8

4. FOUR-FUNCTION SWITCH This four function switch houses the work lamp switch, windshield washer switch, windshield wiper switch, and auto idling switch. It also allows the anti-theft system to be registered and set.

5. HOUR METER/TRIP The machine hour meter registers engine operation hours and tenths of an hour (6 minutes) and allows mai ntena nce in ter va ls to b e c alc ul ated. Th e hourmeter can be read even when the engine is off.

6. STORAGE COMPARTMENT 7. ROCKER SWITCHES (OPTIONAL FEATURES) In machines with special attachments, a rocker switch is provided to select flow rate of the pump.

When the switch is pressed, pump flow is switched to register flow patterns. An attachment icon will also display at the upper right hand corner of the machine monitor (1).

8. 12 VOLT POWER SOURCE A 12 volt power socket supplies power for electric equipment and/or accessories. Use this socket only for equipment with a 12 volt rating.

3-12

CHAPTER 3 - INSTRUMENTS AND CONTROLS RIGHT HAND CONTROL ARM

12 9

10

14

13 15 11

9 Figure 24

CT06K22

12. STARTER SWITCH

9. OPTION CONTROL (IF EQUIPPED) 10. ENGINE IDLE SPEED SELECTOR

The starter switch has four positions:

This control enables automatic engine idle without operating the throttle button. To select idle speed, press and rel ease the control for the engi ne automatically to go into idle speed. The message “Eng. Idling” will appear on the monitor display panel (1). When the control is pressed and released once more the engine will revert to its original speed and the message on the monitor display panel will disappear.

Start: Engine starting position.

11. ARM ANGLE ADJUSTMENT LEVER This lever is used to adjust the control arm tilt to suit the operator. Pull the lever to the right and hold in this position, tilt the control arm to the desired position and release the lever.

WARNING Unexpected machine movement!

The engine must be OFF when you adjust the control arm.

Failure to comply could result in death or serious injury W0273A

ON: Engine running position (electrical system also energized).

Access or y : En gine in stoppe d pos iti on wi th accessory power on.

OFF: All systems are off and the key can be inserted or removed in this position.

S e e “ S t a r t i n g t h e e n g i n e” i n t h e “ O p e r a ti n g Instructions” Section.

NOTICE: When the starter switch key is in the “ON” position, if the anti-theft device has been programmed, then it will be necessary to enter the password code. The message “Password” will be displayed. See “Anti-theft device” in the Operating Instructions Section.

13. ENGINE ACCELERATION AND WORKING MODE SELECTION CONTROL BUTTON This button allows an increase or reduction of the engine speed. The button is coupled with the three working mode selectors. Mode “A” (automatic) balances between the speed and energy output for each movement of the controls. Automatic mode is the most fuel efficient. Mode “H” is designed for normal excavation work when the load increases.

Use SP or speed priority mode when operating in a speed priority situation.

14. ROTARY BEACON CONTROL (OPTIONAL) Use this switch to turn an optional rotary beacon on or off.

15. RADIO COMPARTMENT An AM/FM radio (not shown) is included with this machine.

3-13

CHAPTER 3 - INSTRUMENTS AND CONTROLS RIGHT FRONT CONSOLE CONTROLS

1. Climate Control Light Sensor NOTICE: Do not block the light sensor, as the automatic climate control system is dependent on the light sensor for optimum operating efficiency.

2. Clock

1

The digital clock can be adjusted by pressing the “H” key for hours (1-12) and the “M” key for minutes (0 to 59). Press the “M” key continuously to reset the clock.

2

3. Air Vents The vents control the circulation and direction of air flow. The vents are opened and controlled manually.

3

4. Storage Compartment 5. Cigarette Lighter

3 4

5

CT06K023

3-14

Figure 25

Press the lighter in and release to activate. Do not hold the lighter in. If the lighter does not come out after 30 seconds, pull it out manually, as it may damage the electrical circuit. When the lighter has been removed the socket can be used as a 24 volt electrical socket.

CHAPTER 3 - INSTRUMENTS AND CONTROLS LEFT HAND CONTROL ARM

1

2 3

4

4 8

6

7

9 5 Figure 26

CT06024

1. Emergency Stop Switch

5. Radio Mute

This control enables the engine to be shut off in an emergency or when it is not possible to shut it down by means of the starter key. Press on the front of the control, the engine stops, the audible warning device sounds, the control indicator lamp comes on. The message “Engine stop” is displayed on the monitor, see “Message display”. To start the engine again, press on the back of the control once more and then turn the starter switch key to start the engine.

Located beneath the control lever, this control is used to mute the sound without having to operate the radio. Press and release the control to mute the radio sound. Press again on the control and release, and the sound is restored.

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

This lever is used to adjust the control arm tilt to suit the operator. Pull the lever to the rear and hold it in this position, tilt the control arm to the required position and then release the lever.

2. Function Cancellation Lever This lever is used to cancel the functions without having to raise the control arm. It is also used to operate the safety bar. See “Function cancellation lever and safety bar” in this section. This lever also makes it possible to raise the control arm completely, which also cancels all machine functions.

3. Horn To sound the horn, press the lower switch control as indicated on the left hand control lever.

NOTICE: Always sound the horn before operating the machine.

4. Option Control

NOTICE: If the engine is stopped and restarted, the sound will return to an audible state.

6. Arm Angle Adjustment Lever

WARNING Unexpected machine movement!

The engine must be OFF when you adjust the control arm.

Failure to comply could result in death or serious injury.

W0273A

7. Ashtray Pull ashtray upward to empty.

8. Climate Control System See “Climate Control” in this section.

9. Safety Cancellation Lever The safety cancellation lever prevents the hydraulic controls of the machine from operating when in the locked position. When exiting the cab, push the lever down to lock the controls. Pull the lever up when the controls should be operable.

3-15

CHAPTER 3 - INSTRUMENTS AND CONTROLS FUNCTION AND MESSAGE DISPLAY SCREEN

Figure 27

CT06K027

1. ENGINE COOLANT TEMPERATURE INDICATOR Temperature of the coolant is defined by the increase or the decrease in the number of lighted vertical bars.

Zone “C” indicates that the engine coolant temperature is cool. If the luminous bars reach zone “H” (hot), the audible alarm device sounds and the message “Over Heat” is displayed (see “Message display”). Stop the engine, remove the starter switch key, and find the cause of the problem.

2. HYDRAULIC FLUID TEMPERATURE INDICATOR Temperature of the hydraulic fluid is defined by the increase or the decrease in the number of lighted vertical bars. Zone “C” indicates that the hydraulic fluid temperature is cool. If the luminous bars reach zone “H” (hot), the audible alarm device sounds and the message “Over Heat” is displayed (see “Message display”). Stop the engine, remove the starter switch key and find the cause of the problem.

3. FUEL LEVEL INDICATOR The quantity of fuel is defined by the number of lighted vertical bars. Zone “F” shows that the fuel tank is full. If the bars decrease to zone “E” (Empty), the audible alarm device sounds and the message “Low Fuel” is displayed (see “Message display”).

Use suitable fuel, see “Fluids and lubricants” in section 5.

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

WORKING MODE INDICATOR This indicator displays the initial working mode and the engine speed selected by the engine acceleration button and the working mode selector. See item 2 under “Right-hand control arm”.

4. ERROR CODE INDICATOR This indicator displays the error code number should a problem occur. If an error code is displayed, shut down the engine, remove the key switch and contact your CASE Dealer.

5. ANTI-THEFT PROTECTION INDICATOR This icon is dis played when anti-theft protection is activated. See “Anti-theft protection” in this section.

6. OPERATING ICONS Engine idling Pressure increase Automatic heating Fan ON

Engine preheat 7. ACCESSORY ICON Displays the type of accessory in use by the machine (i.e. hydraulic hammer, etc.).

3-16

CHAPTER 3 - INSTRUMENTS AND CONTROLS MESSAGE DISPLAY

BD00J056

Figure 28

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.

ENG. PRE HEAT - This message shows that the engine needs pre-heating and it is necessary to warm up the engine. The length of time this message remains is dependent on the coolant temperature. As soon as the engine reaches starting temperature, the message will disappear.

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.

ENG. IDLING - This message shows that the engine idle speed selector has been operated and that the engine is running at idle speed.

POWER UP - This message shows that maximum attachment power has been automatically requested.

SERVICE DUE - This message shows that servicing is due. The message will appear five times for a minute upon starting the engine. See the “Servicing Intervals” Section 5.

LOW FUEL - 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.

3-17

CHAPTER 3 - INSTRUMENTS AND CONTROLS MESSAGE DISPLAY

BD00J056

Figure 29

LOW COOLANT - This message shows that the engine coolant level is low. The audible alarm device also sounds. Shut the engine off, remove the starter switch key, allow the system to cool, and then check the coolant level in the expansion reservoir and the radiator. See “Cooling System” 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 the engine off, remove the starter switch key and check the oil level. 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.

The audible alarm device also sounds. Reduce engine speed. If the temperature does not drop, shut the engine off, 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 the engine off, 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 the engine off, remove the starter switch key and find the cause of the problem, or see your CASE Dealer. See the “Electrical System” Section.

ENGINE AIR FILTER - The message shows there is a fault in the engine air filter. The audible alarm will sound.

Air has been restricted and requires immediate service. Shut the engine off, and remove the starter switch key.

See the “Lubrication and Maintenance” Section.

CHECK ENGINE - Indicates engine problems such as a short-circuit and/or break in the electrical system.

Check engine electric circuit related items.

BOOST TEMPERATURE HIGH - This message shows temperature of boost air to engine is high. Stop machine operation without stopping engine, as the engine will run at low idle until temperature drops. The engine will stop automatically if boost air temperature increases while message is displayed.

CHECK HYDRAULIC OIL FILTER - This message shows that the hydraulic return filter should be replaced or is blocked. The audible alarm device also sounds. Shut the engine off, remove the starter switch key, and find the cause of the problem.

SECURITY ON - This message indicates the anti-theft password has been set. Enter password before starting engine.

ENGINE STOP - The emergency stop switch for the engine is turned ON. Turn the emergency stop switch off prior to starting the engine.

3-18

CHAPTER 3 - INSTRUMENTS AND CONTROLS

1

TRIP

ODO

12345.6

1/10H

AUTO

n n/min

Figure 30

BD07A230

TRAVEL SPEED SELECTOR - This is a push button for changing from high speed to low speed and low to high. A confir mation message appears on the indicator. When high speed is chosen the indicator light (1) to the upper left of the switch will illuminate.

In low speed the indicator light is off.

WARNING Unexpected movement!

All changes in travel speed should be made while the machine is stopped (stationary). Changes in speed while the machine is in motion can cause unexpected movement.

Failure to comply could result in death or serious injury.

CT06K026

TRIP

Figure 31

HOUR METER -The hourmeter displays the total time that the engine has been operated in hours and tenths of an hour. The last digit corresponds to 1/10 of an hour (6 minutes). The hour meter also enables ser vice operations to be scheduled at correct inter vals (See the “Lubr ication/Maintenance” Section).

TRIP SWITCH When the TRIP switch is pressed, the trip function will be indicated on the console. In approximately one minute, the trip indicator will revert back to the hour m e t e r. P r e s s a n d h o l d t h e t r i p sw i t c h fo r approximately two seconds when the trip meter is displayed to reset the trip at “0.0”.

Low speed (I), 0 to 3.5 km/hr (0 to 2.2 mph) Select this speed to travel on slopes, rough ground or soft terrain.

High speed (II), 0 to 5.6 km/hr (0 to 3.5 mph). Select this speed to travel on hard, flat ground in good terrain conditions.

NOTICE: When starting the engine, low speed is automatically selected.

NOTICE: When the hydraulic system is overloaded and the machine is in second speed, the machine automatically drops down to first speed. The system automatically returns to second speed as soon as the hydraulic system is no longer overloaded.

3-19

CHAPTER 3 - INSTRUMENTS AND CONTROLS

CONTROL SWITCH

4. Auto Idling Switch: When the idle auto switch is pressed, the switch will sound as it switches from normal to auto idling.

2

Normal mode: The indicator lamp located to the lower right of the switch will not be illuminated.

1

3

Auto Idling: The indicator lamp located to the lower right of the switch will illuminate. When auto idling is selected, the engine will run at low idling speed after approximately 5 seconds with t h e c o n t r o l l eve r a t t h e n e u t r a l p o s i t i o n .

Operation of the control lever or the throttle volume will allow the engine to return to the original speed automatically.

If the engine is switched off, the idling chosen during shut down will be held at restart. This switch does not have a default.

4 WASHER

Figure 32

This four function control switch operates the windshield washer, windshield wiper, work lamps, and the automatic idling switch. It also can be used to enter the password code if the anti-theft device has been set.

NOTICE: The windshield washer and/or wiper will not activate with the front window open.

1. Washer Switch: When the switch is pressed, washer fluid is sprayed and the wipers are activated. The washer fluid reservoir is located in the left hand compartment behind the cab and can be lifted out of its support.

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

2. Windshield Wiper Switch: T h i s sw i t c h h a s t h r e e p o s i t i o n s : “ O f f ” , “Intermittent” and “Continuous”. Press the switch for intermittent operation, the left lamp comes on.

Press the switch again to obtain continuous operation, the right lamp will come on. Press the switch once more for the function to cease.

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

3. Work Lamp Switch: Press the switch to turn work lights on. Press again to turn lights off.

3-20

CHAPTER 3 - INSTRUMENTS AND CONTROLS

ANTI-THEFT DEVICE To help prevent the machine from being stolen, use the anti-theft system which makes it necessary for a special code to be entered before the machine can be operated.

Your Case Dealer has to supply and activate the system for it to be operational. Once this operation has been performed, a special access code must be entered each time you start the engine.

NOTICE: Once the code has been entered, do not forget it, as it can not be changed without consulting your Case Dealer.

NOTICE: Programming the anti-theft device is an option that is solely up to the owner/operator. If the device is not activated, the engine can be started without entering a password.

SETTING THE CODE 1. Stop the engine and move the starter switch from ON to OFF to ON to OFF within 2 seconds. A buzzer will sound and a padlock icon will appear on the top right of the monitor.

THEFT2

CONSOLE THEFT

Figure 33

2. A buzzer will sound and a padlock icon will appear on the top right of the monitor. Enter the password number prior to starting the engine.

Figure 35

4. Use the control switch to enter the registered numerical password. The code will appear on the screen.

(1) Washer switch shifts the cursor to the left.

(2) Work lamp switch shifts the cursor to the right.

(3) Wiper switch increases the code number.

(4) Auto idling switch decreases the code number.

(5) Press the travel mode switch to confirm the entry.

5. If the entered password number is different from the number registered, the ERROR message will display on the monitor. The machine can be started, but when an attempt is made to operate the machine, the engine will shut down.

PASS1

Figure 34

ENTERING THE ACCESS CODE NOTICE: If the anti-theft device was activated the last time the engine was shut down, then it will be necessary to enter the access code before being able start the engine again.

3. The message “Password” and four boxes will appear on the display screen.

3-21

CHAPTER 3 - INSTRUMENTS AND CONTROLS

AUTOMATIC TEMPERATURE CONTROL SYSTEM These controls are located on the left-hand control arm.

6

3

9

R/F

A/C

AUTO

7 MODE

AUTO TEMP

2

ON

DEF

OFF

4

1

8

5 Figure 36

CS06K016

1. On/Off

6. Air recycling

2. Automatic

7. Air flow direction control

3. Air conditioning

8. Windshield defroster

4. Fan speed

9. Display screen

5. Temperature NOTICE: Temperature may be displayed in Celsius or Farenheit. Press and hold both buttons (5) simultaneously for five seconds to display in Celsius or Farenheit.

ON/OFF FAN SPEED

9 A/C

AUTO

A/C

AUTO

AUTO TEMP

AUTO

ON OFF

TEMP

4

ON OFF

1 CS06K016

Figure 37

This push button (1) is for turning the system on or off.

NOTICE: When the system is turned on, it will operate at the same setting as selected for previous use.

3-22

CS06K016

Figure 38

These push buttons (4) allows the air flow to be increased or reduced. To increase the flow of air, press the top button. To decrease the flow of air, press the lower button. The bars on the display screen (9) will increase or diminish, depending on the flow selected.

CHAPTER 3 - INSTRUMENTS AND CONTROLS AIR FLOW DIRECTION

TEMPERATURE

9

9 R/F

AUTO E

AUTO

MODE TEMP

TEMP

DEF

7 5 Figure 39

CS06K016

Figure 41

CD00E050

These push buttons (5) allow the temperature to be raised or lowered within an 18° to 32°C (64° to 89°F) range. To increase the temperature, press the right-hand button. To lower the temperature, press the left-hand button. The temperature reading will appear on the display screen (9).

This button (7) allows four different types of air flow direction to be selected.

- Via the top front air vent.

- Via the top front and rear air vents.

- Via the top and lower rear air vents.

- Via the lower rear and wind shield air vents.

NOTE: Press both buttons (5) simultaneously for five seconds to display the temperature in C° or F°.

To select the type of air flow direction, press the button (7) successively until the type of flow direction required is obtained. Indication of the type of flow direction selected will appear on the display screen (9).

AIR RECYCLING

6 R/F

WINDSHIELD DEFROSTER

99

9

AUTO

MODE

R/F TEMP

DEF

AUTO

MODE TEMP

DEF CD00E050

Figure 40

This button (6) allows two different types of air circulation to be selected. Fresh air from the outside or recycled air from within. Each time the button is pressed, the type of circulation will be changed.

Indication of the type of circulation selected will appear on the display screen (9).

8 CD00E050

Figure 42

This button (8) allows the wind shield to be defrosted.

Press the button to defrost the wind shield. Indication that the defroster is working will appear on the display screen (9).

To turn the defroster off, press the button once more and the indic ation on the display scr een will disappear.

3-23

CHAPTER 3 - INSTRUMENTS AND CONTROLS AIR CONDITIONING NOTICE: When using the air conditioning, it is essential for all the operator’s compartment windows, the windshield and the cab door to be kept closed.

The air vents must be kept in open position. If the cab door or front window is opened, the AC system will select the face vent as the flow direction and reduce the fan speed automatically.

MANUAL

6

3

9 AUTO

The air conditioning can function in two modes, manual and automatic.

TEMP

AUTOMATIC

7 2

9

5 CS06K016

A/C

AUTO

AUTO TEMP

ON OFF

5 CS06K016

4 Figure 44

This button (3) is used to turn the air conditioning on and off. When the air conditioning is running, confirmation is given on the display screen (9).

Manual adjustments can be made using controls (4), (5), (6) and (7).

CLIMATE CONTROL SENSOR

1 Figure 43

T h i s bu t t o n ( 2 ) i s u s e d t o o b t a i n a u t o m a t i c adjustment of the temperature, the volume and the direction of flow of the air. In this case, “Auto” will appear on the display screen (9). In automatic mode, the only possible manual adjustment is to the temperature (5). All other adjustments are made automatically.

If any adjustment other than to temperature is made, the automatic mode is cancelled and “Auto” disappears from the display screen (9). To shut down the system, press buttons (1) or (2).

CD00E051

Figure 45

The temperature and light sensor is located on the right front console. Do not block the light sensor, as the automatic climate control system is dependent on the light sensor for optimum operating efficiency.

NOTICE: To insure 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.

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

3-24

CHAPTER 3 - INSTRUMENTS AND CONTROLS RADIO

Figure 46

GRAPHIC_1D

1. Power Switch/Volume Control Turn the knob clockwise. A click sound will indicate the power is on. Volume is increased as the knob is turned clockwise once power is on.

2. Tone Control Turning the knob counter clockwise will decrease high sound interference and correct tone.

3. Display Station selection and/or clock time will be displayed. Station is displayed as radio is tuned.

When a station is selected, after a few seconds, the time will display.

4. Clock button Press to display time. Press again to return to station frequency display.

5. Auto Store Memory This two function button is used to preset memor y scan. The radio will receive a pre-programmed station for a few seconds and then scan to another pre-programmed station.

Pressing the button again will stop the scan feature. Press the button for longer than two seconds, and it enables the auto store memory feature.

6. Preset Stations AM and FM band station can be preset for each of the six keys. See “Presetting Stations.”

7. Seek P r e s s t h e s e e k bu t to n a n d t h e ra d i o wi l l automatically search for a receivable station and automatically stop once a station is found. Press again to seek another station.

8. Band Select Use this button to select either AM or FM stations.

9. Tuning This is an additional tuning feature. Press either UP or DOWN to shift the tuner step by step.

NOTICE: Do not allow water to get inside the speakers or the radio. It can cause irreparable damage. Do not use cleaning solvents on the radio face plate. Wipe with a soft, dry cloth. Do not attempt to disassemble the radio.

3-25

CHAPTER 3 - INSTRUMENTS AND CONTROLS Presetting Radio Stations

Setting the Radio Clock

1. Select the desired station either by manual or seek tuning.

1. Turn the machine accessory switch to the ON position and turn the radio on.

2. Press and hold the memory button (5) for over two seconds.

2. Press the CLOCK button. If the display was indicating a radio station, it will now display the time.

3. Repeat steps 1 and 2 to preset other stations.

Six stations can be preset on the AM band and six stations on the FM band.

NOTE: If machine battery fails or electrical work is done on the machine which requires removing the battery, all preset features will be lost and must be reset.

3. Press the M button while holding the clock button to change the minutes. Pressing the H button while holding the clock button down will set the hour.

4. When the correct time is reached, release the M/H and Clock button to lock in the time.

Radio Mute Switch

CT06K031

Figure 47

A muting switch can be found on bottom of the left hand control lever. Pressing this switch will mute the radio sound without having to touch the radio. Press the button again and release and the sound will be restored. If the engine is stopped with the sound muted, it will return to an audible state when the engine is restarted.

3-26

CHAPTER 3 - INSTRUMENTS AND CONTROLS ARM AND UPPER STRUCTURE SWING CONTROL LEFT-HAND CONTROL LEVER

1 9

4

3

2 SWING LEFT

ARM OUT

3

1 SWING RIGHT

ARM IN

2

4 Figure 48

BC00J123

1.Arm out

3.Swing left

2.Arm in

4.Swing right

9.NEUTRAL (HOLD) When the control levers are returned to NEUTRAL (HOLD), all movement stops.

When released, both control levers retur n to NEUTRAL (HOLD) automatically.

NOTICE: When the upper structure swing control is released it may continue to rotate due to the force of inertia. Make allowance for the extra movement by releasing the control slightly earlier

.

3-27

CHAPTER 3 - INSTRUMENTS AND CONTROLS BOOM AND BUCKET CONTROL RIGHT-HAND CONTROL LEVER

5 9

7

8

6 BUCKET RETRACT

BOOM DOWN

7

5 BOOM UP

BUCKET EXTEND

6

8 Figure 49

BC00J122

5.Boom down

7.Bucket close (retracts)

6.Boom up

8.Bucket open (extends)

9. NEUTRAL (HOLD) When the control levers are returned to NEUTRAL (HOLD), all movement stops.

When released, both c ontrol levers retur n to NEUTRAL (HOLD) automatically.

NOTICE: When the upper structure swing control is released it may continue to rotate due to the force of inertia. Make allowance for the extra movement by releasing the control slightly earlier

3-28

CHAPTER 3 - INSTRUMENTS AND CONTROLS OPTIONAL CONTROL PATTERN ARM AND UPPER STRUCTURE SWING LEFT-HAND CONTROL LEVER

1 9

4

3

2 BOOM DOWN

SWING LEFT

3

1 BOOM UP

SWING RIGHT

4

2

Figure 50

BC00J125

1.Boom down

3.Swing left

2.Boom up

4.Swing right

9. NEUTRAL (HOLD) When the control levers are returned to NEUTRAL (HOLD), all movement stops.

When released, both control levers retur n to NEUTRAL (HOLD) automatically.

NOTICE: When the upper structure swing control is released it may continue to rotate due to the force of inertia. Make allowance for the extra movement by releasing the control slightly earlier.

3-29

CHAPTER 3 - INSTRUMENTS AND CONTROLS OPTIONAL CONTROL PATTERN BOOM AND BUCKET RIGHT-HAND CONTROL LEVER

5 9

7

8

6 ARM OUT

BUCKET RETRACT

7

5 ARM IN

BUCKET EXTEND

6

8

Figure 51

BC00J124

5.Arm out

7.Bucket close (retracts)

6.Arm in

8.Bucket open (extends)

9. NEUTRAL (HOLD) When the control levers are returned to NEUTRAL (HOLD), all movement stops.

When released, both c ontrol levers retur n to NEUTRAL (HOLD) automatically.

NOTICE: When the upper structure swing control is released it may continue to rotate due to the force of inertia. Make allowance for the extra movement by releasing the control slightly earlier

3-30

CHAPTER 3 - INSTRUMENTS AND CONTROLS

TRAVEL CONTROL LEVERS AND PEDALS

Figure 52

BD00M485

Figure 55

If the pedal is placed in the half locked position, the pedal can be operated in one direction only. In the example the pedal is locked mechanically on the r eve r s e s i d e a n d o n l y fo r wa r d tr ave l c a n b e performed.

TRAVEL CONTROL LEVERS

TRAVEL PEDALS

CD00E012B

BS07A423

Figure 53

Push the top of the pedal for FORWARD travel. Push the bottom of the pedal for REVERSE. Both tracks will move at the same speed.

PEDAL OPERATION (Option pedal)

BB07A424

Figure 56

In the non locked position, the pedal can be operated in both directions, forward and reverse.

When switching pedal operation, pull the lock lever (A) to change operating position.

For machine travel, see “Machine Travel” in the “Operating Instructions” Section.

NOTICE: Travel speed either forward or in reverse depends on the position of the travel speed selector.

See “Systems display panel”.

BS07A422

Figure 54

Put the pedal at the locking position (1) when it is not in operation.

NOTICE: The movements of the machine are shown in the “Control functions” decal. See “Decals” in the “Safety/Decals/Hand Signal” Section. Make certain the decal and the movement patterns match by operating the machine in a level, unobstructed area clear of unauthorized personnel.

Ask your CASE Dealer for advice on optional tools.

3-31

CHAPTER 3 - INSTRUMENTS AND CONTROLS FUSE BOX

F

1

CT06M006

Figure 57

Quick Coupler Locking and Unlocking Control Switch (Optional) The quick coupler switch is located on the left-hand control arm.

CT06K036

Figure 58

The fuse box is located behind the operator’s seat. To access the fuses, open the covering panel.

To unlock, pull the locking pin (1) towards you and simultaneously press the top of the switch. The audible alarm will sound, and in this position the tool can be installed or removed.

To lock, press the bottom of the switch. The audible alarm will turn off. When locking, it is not necessary to operate the locking pin (1).

NOTICE: Each time a tool is changed, make certain the switch is in the locked position.

CT06K037

Figure 59

Always replace fuses with fuses of the same amperage. To replace a fuse, see fuses in the Electrical Section of this manual.

3-32

CHAPTER 3 - INSTRUMENTS AND CONTROLS

CAB FEATURES CAB LIGHT CAB DOOR SLIDING WINDOWS

CT06K34

Figure 60

The light is located on the left-hand cab upright and is controlled by a three-position switch. In addition to having “ON/OFF positions, the intermediate (center) position allows the light to turn off 30 seconds after closing the door.

NOTICE: Make certain light turns off in order to avoid battery discharge.

CT06K044

Figure 63

When the locks are released, the windows can be opened and closed to the front or rear as required.

CUP HOLDER

COAT HANGER

CT06K043

CT06K035

Figure 61

This hook is on the right-hand cab upright. Take care not to obstruct operator’s view with hanging articles.

STORAGE COMPARTMENTS

LITERATURE RACK

CT06K040 CT06K042

Figure 62

Storage compar tments are located behind the operator’s seat on the right and left hand sides.

Figure 64

Located on the front right hand side of the operator’s seat, the holder is designed to hold a beverage container.

Figure 65

A literature slot is located on the right hand side behind the operator’s seat.

3-33

CHAPTER 3 - INSTRUMENTS AND CONTROLS STORAGE COMPARTMENT

ROOF CURTAIN (Optional Skylight)

CT06K038

Figure 66

Figure 68

CT06K040

To open, slide the curtain towards the rear of the cab using the handles.

A storage compar tment is located behind the operator’s seat.

ROOF HATCH (Optional)

EMERGENCY EXIT (Rear Window)

2 1

CD00E015

Figure 67

Open the roof cur tain. To open the roof hatch, release the handle, and push the hatch upwards. To close the roof hatch, pull the handle and latch in place.

NOTICE: The roof hatch closing is assisted by two gas struts, Follow through the closing movement only. Do not force.

Figure 69

CT06K054

To open the emergency exit, pull on the ring (1) and release the seal (2) from the frame of the rear window. Push firmly outwards. Be proactive and familiarize yourself with this exit. (Do not open the window unless absolutely necessar y. The rear window will have to be reinstalled should it be necessary to open it in an emergency situation.)

WARNING Escape hazard!

The rear window is an emergency exit. Remove the rear window only in an emergency. Do not place any object in front of the window that could be an obstacle in case of evacuation.

Failure to comply could result in death or serious injury.

3-34

CHAPTER 3 - INSTRUMENTS AND CONTROLS WINDSHIELD CLOSING

SUN SCREEN

Figure 70

CT06K051

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

TO OPEN THE WINDSHIELD

CD00E052

Figure 73

Use the lever to release the windshield. Hold both handles and carefully lower the windshield. Make certain the window is completely down. Make certain the top of the windshield is correctly latched.

LOWER FRONT WINDOW

2

1

CT06K051

Figure 71

Fold the sun screen back against the windshield and operate the lever (1). Hold the lower and upper handles (2) and carefully raise the windshield.

CT06K052

CT06K053

Figure 74

The lower front window should only be removed when the upper windshield is open. Remove the window from its housing by sliding upwards.

Figure 72

Pull the windshield to the rear until it engages behind the cab.

CD0E022

Figure 75

Place the window in the storage position to the left of the operator’s seat, making certain it is securely engaged.

3-35

CHAPTER 3 - INSTRUMENTS AND CONTROLS ENGINE SIDE DOORS

WARNING

LEFT-HAND DOORS

Avoid injury!

Never leave tools or other objects behind the side doors.

Failure to comply could result in death or serious injury.

ENGINE HOOD OPENING

CAUTION Figure 76

CT07K028

The windshield reservoir is located in the rear left hand compartment. It is equipped with an electric pump which is operated from the control panel.

Never operate the windshield washer when the reservoir is empty. This can cause damage to the pump.

Falling engine hood can cause injury!

Engage the hood lock when the hood is open.

Failure to comply could result in minor or moderate injury.

CD00E039

Figure 78

Release the hood latches, then lift the hood to the maximum height in order to automatically lock with the support strut.

Figure 77

CD01N018

The right-hand door gives access to certain hydraulic components (pump, filter, etc.) and also to engine fuel and oil filters.

CLOSING

NOTICE: Always install the struts when doors are open to hold doors securely in place.

WARNING Avoid injury!

Before undertaking any travel you must close and secure the side doors.

Failure to comply could result in death or serious injury.

3-36

CD00E039

Figure 79

Lift the hood slightly, pull the support strut back, then lower the hood and lock in place with hood latches.

CHAPTER 3 - INSTRUMENTS AND CONTROLS FRONT STORAGE BOX

CT06K063

Figure 80

The hood may be locked with the starter key at the hood latch.

NOTICE: Always close and secure hood before undertaking any travel.

REAR VIEW MIRRORS

Figure 82

CT06K057

The storage box is to the right in front of the upper structure frame. It is used for storing spare or service par ts and gives access to the upper structure working light.

NOTICE: Use the starter switch key to lock and unlock the storage box cover.

WARNING Moving parts!

Make sure that the storage box cover is closed properly before driving the machine.

Failure to comply could result in death or serious injury.

CD00E036

Figure 81

Before undertaking any travel, make sure the rear view mirrors are clean and properly adjusted.

NOTICE: The left side mirror must be folded for transport.

3-37

CHAPTER 3 - INSTRUMENTS AND CONTROLS FUEL TANK

CT06K098

Figure 83

RD00K032

Use the correct fuel grade for the operating season.

The starter switch key is used to lock and unlock the cap.

NOTICE: In cold weather, use fuel corresponding to the ambient temperature. See Fluids and Lubricants in the Lubrication/Filters/Fluids Section.

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

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

NOTICE: Clean around the fuel cap before refuelling and do not remove the screen located in the filler orifice except to clean. See Fuel Tank Filter in the “Maintenance Adjustments” Section.

WARNING Fire hazard!

When handling diesel fuel, observe the following precautions: 1. Do not smoke.

2. Never fill the tank when the engine is running.

3. Wipe up spilled fuel immediately.

Failure to comply could result in death or serious injury..

W0099A

3-38

Figure 84

The fuel tank is equipped with a visual gauge for monitoring fuel level from the ground.

CHAPTER 3 - INSTRUMENTS AND CONTROLS HOSE BURST CHECK VALVE (OPTIONAL)

LOWER PANELS

SERVICE SPECIFICATIONS Check by your CASE Dealer . . . . . . Every 6 months

Figure 85

CT06M010

These steel panels are located under the upper structure frame and give access to certain machine components.

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

WARNING Moving parts!

Make sure that the lower panels are properly closed before machine travel.

Failure to comply could result in death or serious injury.

W0910A

WINDSHIELD WASHER RESERVOIR

CT06K062

Figure 87

CT06K065

The role of the load holding 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.

Should a hose break or burst, the holding valve also insures that the attachment may be lowered slowly to the ground. See “Load Handling” in the “Operating Instructions” Section.

WARNING Cylinder mounted load holding control devices are pilot operated devices. The operator MUST return the control lever to the neutral position to prevent the attachment and load from falling in the event that a hydraulic hose or line fails.

Failure to comply could result in death or serious injury.

Figure 86

This reser voir is located in the left hand rear compartment. It is equipped with an electric pump which is operated from the control panel. See Systems Display and Control Panel section NOTICE: 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. In cold weather, add anti-freeze to the windshield washer water.

3-39

CHAPTER 3 - INSTRUMENTS AND CONTROLS LOAD LIFTING EYE

TOWING HOLES

Figure 88

CD00E069

The towing hole, located at the front and the rear of the undercarriage is intended for moving heavy objects.

WARNING Towing hazard!

Towing is a delicate maneuver that is always carried out at the risk of the user. The manufacturer's warranty does not apply to incidents or accidents that occur during towing. Where possible, carry out the repairs at the site.

Failure to comply could result in death or serious injury.

WARNING Towing hazard!

The towing operation must be carried out very slowly, over a short distance and only if it is really unavoidable.

Failure to comply could result in death or serious injury.

Make sure that the shackles, chains and tackle are in perfect condition and strong enough to move the load.

IMPORTANT: The load should always be kept in line with the undercarriage.

3-40

Figure 89

BD00J053

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

NOTICE: This load lifting eye will only carry the load indicated in the maximum lift chart. See “Lift Charts” in the “Specifications section” of this manual.

NOTICE: No load lifting may be performed with the tracks and side frame in the transport position.

WARNING Falling object hazard!

Never weld hooks or lugs on the bottom plate of the bucket for handling operations. The connecting rod eye is the only authorized attachment point. Always have a bucket installed when using the connecting rod eye.

Failure to comply could result in death or serious injury.

W0246A

CHAPTER 3 - INSTRUMENTS AND CONTROLS

WARNING The Protective Structure and interconnecting components are a certified system. Any damage, fire, corrosion or modification will weaken the structure and reduce your protection. If this occurs, the Protective Structure MUST be replaced so that it will provide the same protection as a new Protective Structure. Contact your dealer for Protective Structure inspection and replacement.

After an accident, fire, tip over, or roll over, a qualified technician MUST replace the Roll Over Protect Structure (ROPS) before returning the machine to the field or job site.

DO NOT WELD, DRILL HOLES, ATTEMPT TO STRAIGHTEN OR REPAIR THE PROTECTIVE STRUCTURE. MODIFICATION IN ANY WAY CAN REDUCE THE STRUCTURAL INTEGRITY OF THE STRUCTURE WHICH COULD CAUSE DEATH OR SERIOUS INJURY IN THE EVENT OF FIRE, TIP, ROLLOVER, COLLISION OR ACCIDENT. CD04D008A

Figure 90

FALLING OBJECTS PROTECTIVE STRUCTURE R O L L OV E R P R OT E C T I V E S T R U C T U R E (OPTIONAL)

Failure to comply could result in death or serious injury.

A FOPS (Falling Objects Protective Structure) ROPS (Roll Over Protection S tr ucture) is an important protective element when work takes place in areas where stones or debris may fall. See your CASE dealer for this protective piece of optional equipment and its proper installation.

3-41

CHAPTER 3 - INSTRUMENTS AND CONTROLS FUEL TANK FILLING PUMP (OPTIONAL)

1 WARNING Fire hazard!

When handling diesel fuel, observe the following precautions: 1. Do not smoke.

2. Never fill the tank when the engine is running.

3. Wipe up spilled fuel immediately.

Failure to comply could result in death or serious injury.

W0099A PDF0361

NOTICE: This optional pump is located in the front storage box and is to be used for fuel only. Use suitable fuel, see “Fluids and Lubricants” in section 5.

Figure 92

3. Measure the height of the drum and place the identification clamp (1) of the suction tube at a length slightly less than that of the drum height.

4. Make sure that the end strainer of the suction tube is correctly attached and then insert the suction tube in the drum.

CT06K068

Figure 91

1. Park the machine on flat, level ground, stop the engine and set the starter switch key to the “ON” position (contact).

2. Take the inlet pipe out of the storage compartment.

3-42

CT06M011

5. Remove the fuel tank filler cap.

Figure 93

CHAPTER 3 - INSTRUMENTS AND CONTROLS

CT06K069

Figure 94

6. Select the filling method using the selector switch located to the r ight of the filling pump. In Automatic or “Auto” mode the pump will stop filling automatically and an audible alarm will sound when the fuel tank is full. In “Manual” mode, the fuel fill operation must be monitored by means of the reservoir gauge and stopped manually when necessary.

CT06K068

Figure 95

7. Turn the switch located on the pump to the “On” position. When the tank is full, switch to the “OFF” position. Run the pump a few moments to empty the pipe making certain it is above drum fuel level. Clean and replace the inlet pipe in the front storage compartment. Replace the tank filler cap.

3-43

CHAPTER 3 - INSTRUMENTS AND CONTROLS

3-44

CHAPTER 4 - OPERATING INSTRUCTIONS

Chapter 4 OPERATING INSTRUCTIONS TABLE OF CONTENTS RUN-IN PERIOD OF A NEW MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 BEFORE OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Walk-Around Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....................................................................................

Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3 4-4 4-4 4-6 4-6 4-6 4-6

BASIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Parking the Machine and Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Starting The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Bringing The Machine Up To Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 CHECKING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Operating The Machine In Cold Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Operating The Machine In Hot Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Stopping The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 MACHINE TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting Loads With The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quick Coupler (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auxiliary Hydraulic circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating The Machine In Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating The Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Towing The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-12 4-15 4-16 4-17 4-20 4-21 4-22 4-23

TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Setting the 3.0 M Dipper into the Transport Position (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

By Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 On A Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

4-1

CHAPTER 4 - OPERATING INSTRUCTIONS

4-2

CHAPTER 4 - OPERATING INSTRUCTIONS

RUN-IN PERIOD OF A NEW MACHINE ENGINE OPERATION During the first 20 hours of operation, or if you rebuild the engine, make sure you do the following: 1. Operate the machine with normal loads for the first eight hours. Do not work the engine hard up to stall speeds.

2. Keep the engine at normal operating temperature.

3. Do not run the engine at idle speeds for long periods of time.

4. Additionally, follow the guidelines for scheduled maintenance in Section 5 - Lubrication and Maintenance.

BRAKE PEDAL Check the operation of the brake on a hard level surface when the machine is new.

WARNING Avoid injury!

Before starting engine, study operator’s manual safety messages. Read all safety signs on machine. Clear the area of other persons. Learn and practice safe use of controls before operation. It is your responsibility to understand and follow manufacturers instructions on machine operation, service, and to observe pertinent laws and regulation. Operator’s and repair manuals can be obtained from your dealer.

Failure to comply could result in death or serious injury.

BEFORE OPERATING THE MACHINE WARNING Avoid injury!

Do not attempt to operate this machine unless you have first read and understand the safety messages and instructions appearing in this manual. Operator’s and repair manuals can be obtained from your dealer.

Failure to comply could result in death or serious injury.

Before operating this machine:

• 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”.

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

• Inspect the machine. Look for any signs of wear,

damage, leakage and check the hoses. Tighten or replace as necessary. See the “Maintenance/ Adjustments” 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 hand holds. Grease, oil, mud or (in winter) ice on the steps and hand holds can cause accidents. Make sure they are kept clean at all times.

• Clean or replace any decals which are illegible.

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

• Make sure all hoods, side doors and lower panels are properly closed.

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

• Remove any obstructions which hinder visibility.

Clean the windshield, the rear view mirrors and the windows.

• Check that no tools or other items have been left

on the machine. Check on the undercarriage and the upper structure and in the operator’s compartment.

4-3

CHAPTER 4 - OPERATING INSTRUCTIONS

• Work out a convenient means of escape from the

machine (emergency exit through the windshield, the rear window glass, side glass) in the event the cab door becomes jammed or the machine turns over.

• Make sure no one is on or under the machine. The operator must be alone on the machine.

• Make sure no one is standing in the machine working area.

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

working area. Stop all operations until everyone has moved away.

• Operate all controls gradually to insure 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.

• See “Handling the Machine” when it is necessary to lift the machine.

MACHINE OPERATION

WARNING Avoid accident and injury!

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

Failure to comply could result in death or serious injury.

• 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 insure 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.

• Do not work near overhead high-voltage electric

lines without checking beforehand that all necessary measures have been taken to respect the minimum safety distances:

• Keep all parts of the machine at least 16 feet (5 meters) away from the power source.

• When working on a public highway, use standard

traffic signs and take into consideration the working range of the upper structure 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”.

4-4

• Do not allow anyone to stand in the machine

• See “Towing the Machine” when it is necessary to tow 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 or bucket for sweeping the ground to level out rubble or push objects creating transversal stress on the attachment.

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

• Dust, smoke or mist can reduce visibility and

cause an accident. Reduce speed or come to a complete halt until visibility has improved.

• In the event of an operating problem or failure,

move the machine to a safe place, lower the attachment to the ground, stop the engine and remove the starter switch key. Place a Do Not Operate tag on the machine. 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 “Stopping the Engine”.

consideration.

See

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

OPERATING INSTRUCTIONS

• 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.

• 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.

• Modify your driving to suit working conditions

(sloping or rough ground), the nature of the ground and weather conditions.

CHAPTER 4 - OPERATING INSTRUCTIONS

• On steeply sloping ground, keep engine at maximum speed.

• When traveling at right angles to the slope, move on to the slope at low speed. Never reduce engine speed when traveling down slopes.

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

• 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.

• The following operations are likely to damage the machine. Do not perform:

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

2. Excavation using the machine’s travel force.

• If earth or mud stays stuck inside the bucket, operate the bucket through it’s full range of travel several times so as to loosen the earth or the mud.

• After work, remove any mud and clean the machine.

• When using the upper structure swing, never change the direction of swing too suddenly.

• When climbing up a slope, place the attachment

about 250 mm (10 inches) above the ground.

When traveling down a slope it is recommended placing the attachment close to the ground in order to drop it down quickly in the event of an emergency or if the machine would begin to slide.

• Avoid turning the machine on steep slopes.

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

• Before changing travel speed bring the machine to a complete halt.

4-5

CHAPTER 4 - OPERATING INSTRUCTIONS ENGINE OPERATION WALK-AROUND INSPECTION Each day perform a walk around inspection of the machine.

1. Check for leaks under the machine.

2. Check for loose, missing, or broken parts.

3. Check the machine and equipment for wear, damage, missing, or broken parts.

4. Check the machine for debris, especially around the engine area and radiator. Make sure these areas are clean.

5. Clean or replace any safety or instructional decals that cannot be read.

6. Clean the steps, hand holds, and operator’s compartment. Remove any loose items in the operator’s compartment.

7. See the Lubrication/Maintenance Chart in this manual, and complete the maintenance items listed as ten hours/daily or at each shift.

STARTING THE ENGINE

DANGER Avoid injury!

Start the engine only from the operator's seat with all control levers in NEUTRAL. Failure to comply will result in death or serious injury.

1. Adjust the seat and fasten your seat belt. Make sure you can operate all pedals with your back against the seat cushion.

2. Make certain the safety bar is in the correct retracted position.

3. Make sure the equipment control levers are in NEUTRAL with the equipment on the ground.

NOTE: The Direction Control Lever must be in Neutral or the engine will not crank. N will be displayed on the left side of the Digital Display.

4. Sound the horn to alert those around the machine that you intend to start.

NOTICE: See Operating in Cold Weather in this manual for starting the engine during cold weather.

5. Turn the key switch to the ON position. Monitor the display panel for gauge and machi ne functions.

6. Turn the key switch to the START position. If the engine star ts and stops, do not engage the starter motor again until the starter motor stops turning.

4-6

NOTICE: Do not operate the starter motor more than 30 seconds at one time. Let the starter motor cool for three minutes before you engage the starter motor again. While the starter motor is engaged, white or black smoke must be seen at the exhaust pipe. If no smoke is seen, check the fuel supply.

7. After the engine starts, check the instruments to make sure the gauge indications are correct.

Run the engine at 1000 rpm until the coolant temperature is warm.

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

This can cause a low operating temperature, which can cause acids and deposits in the engine oil. It is recommended that you run the engine at full throttle when operating conditions permit and when safe.

NOTICE: Turbocharged Engines: If the engine stalls during normal operation, start the engine immediately. This will prevent damage to the turbocharger.

CHAPTER 4 - OPERATING INSTRUCTIONS

BASIC OPERATION 1. Sit in the operator’s seat, and adjust it so that all t h e c o n t r o l s a r e r e a d i l y a c c e s s i bl e. S e e “Operator’s Seat” in the “Controls/Instruments/ Accessories” Section. Then fasten your safety belt.

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

3. Sound the horn to alert those around you that you are starting the machine.

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

5. Check all instruments are operating correctly.

6. Lower the function cancellation lever (safety bar in outward position).

7. Unlock the upper structure swing function.

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

WARNING Avoid injury!

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

Failure to comply could result in death or serious injury.

PARKING THE MACHINE AND STOPPING THE ENGINE 1. When the work day is finished, make sure the machine is parked on level ground.

If you must temporarily park the machine on a hillside, put the front of the machine toward the bottom of the hill. Make sure the machine is behind an object that will not move.

2. Lower the attachment to the ground.

3. Place the Direction Control Levers in NEUTRAL. 4. Run the engine at low idle speed for a few minutes if the engine has been working with a heavy load. This decreases the temperature of the engine parts evenly.

NOTICE: The turbocharger may be damaged if the engine is not properly shut down.

5. Make sure the engine is at its lowest idle.

6. Turn the key switch to OFF to stop the engine.

7. When you park the machine, make sure the track system is clean. In cold weather place the machine on planks. This will prevent the tracks from freezing to the ground.

If your machine is frozen to the ground, do not try to drive the machine. This will cause damage to the power train.

WARNING Avoid injury!

Raised equipment on the machine without an operator can cause injury or death. Before you leave the operator’s compartment, always support or lower the attachment (backhoe, blade, boom, bucket, etc.) to the ground and stop the engine.

Failure to comply could result in death or serious injury.

WARNING Fall hazard!

Jumping on or off the machine could cause an injury. Always face the machine, use the handrails and steps, and get on or off slowly. Maintain a three-point contact to avoid falling: both hands on the handrails and one foot on the step, or one hand on the handrail and both feet on the steps.

Failure to comply could result in death or serious injury.

W0141A

4-7

CHAPTER 4 - OPERATING INSTRUCTIONS STARTING THE ENGINE NOTICE: If the machine has been out of use for some time, see Starting up After Storage.

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

WARNING Explosion hazard!This engine is equipped with a glow plug heater; use of a starting fluid can cause explosion, personal injury or property damage.Failure to comply could result in death or serious injury.

1. Sit correctly in the operator’s seat with the seat belt properly fastened. See “Operator’s Seat” in the “Controls/Instruments/Accessories” Section.

Figure 3

CT06K078

6. In cold weather, the message “Eng. pre heat” appears on the system monitor display.

CT06K029

Figure 1

2. Make sure the function cancellation lever is raised and the safety bar in inward position.

7. When the message disappears, 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 before trying to start the engine again.

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

1 2

CD00E060

Figure 2

3. Make sure the engine throttle button is in low idle position. In cold weather, leave it in half-way position.

4. Turn the start switch key to the “ON” position.

CD00E060

Figure 4

5. If necessary, enter the anti-theft code. See “Anti-theft Device.”

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

NOTICE: Frequently check the systems display and control panel while the engine is running. See “Engine Operation”.

9. Sound the horn button (1) on the left hand control to warn others of your intention to start and move the machine.

10. Push the function cancellation lever (2) forward, the safety bar will now be in an outward position.

4-8

CHAPTER 4 - OPERATING INSTRUCTIONS BRINGING THE MACHINE UP TO OPERATING TEMPERATURE NOTICE: Normal operating temperature of the hydraulic fluid is between 50°C and 80°C (122-176° F), in the middle of the temperature indicator. If the machine is used with the hydraulic fluid at a temperature below 20°C (68° F), damage can occur.

After starting the engine and before using the machine, allow the hydraulic fluid to reach a temperature of 20°C (68° F), as indicated by the appearance of the first bar segment on the hydraulic fluid temperature indicator. See “Systems Display and Control Panel” in the “Controls/Instruments/Accessories” Section.

Engine Automatic Warm-up

Hydraulic Oil Warm-up

Once the engine has star ted, the war ming-up process begins automatically. At first, engine speed is held at a pr edeter mined, 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 depending on the ambient temperature.

Follow monitor prompts.

Turn the engine throttle button to half-open position.

Operate the bucket control slowly until the bucket is completely closed. Operate the arm retracting control slowly until the arm is completely retracted and hold the control in this position for 30 seconds. During this time the temperature of the hydraulic fluid will increase.

Engine Manual Warm-up

Continue the extending and retracting procedure until the temperature rises. See “Systems Display and Cont rol Pa nel ” in the “C ontr ols /Ins tr um ents / Accessories” Section.

With the engine throttle button in low idle, start the engine and allow it to run approximately for 5 to 10 minutes. When the coolant temperature increases, carry out the hydraulic fluid warm-up procedure.

After 30 seconds, extend the arm completely and hold the control in this position for an additional 30 seconds.

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

CHECKING ENGINE When the engine has started and before beginning work, the following procedure must be observed :

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

• Let the engine run at idle speed until the engine

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

• Move the engine throttle button to the maximum

Check the systems display and control panel regularly.

• Once normal operating temperature has been

S TO P T H E E N G I N E I M M E D I AT E LY I N T H E FOLLOWING SITUATIONS:

and hydraulic oil reaches normal operating temperature. speed position.

reached, check the following :

1. The exhaust smoke is normal.

2. There is no abnormal noise or vibration.

3. There are no oil, fuel or water leaks.

• • • •

Sudden increase or decrease in engine speed.

Abnormal noise.

Black smoke at the exhaust.

A message appears on the display screen and the audible alarm device sounds.

4-9

CHAPTER 4 - OPERATING INSTRUCTIONS OPERATING THE MACHINE IN COLD WEATHER Cold weather conditions cause special problems.

During these conditions, your machine will require special attention to prevent serious damage. Cold weather maintenance will extend the service life of your machine.

Batteries and Electrical System Batteries should be fully charged for optimum cranking capabilities. A fully charged battery at 17° C (0° F) has only 40 percent of the normal starting power. When the temperature decreases to -29° C (-20° F), the battery has only 18 percent of the power remaining.

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. b) To prevent crystals forming at -2°C (29° F), use fuel which is rated for the ambient temperature.

Consult your fuel dealer for the correct mixture for temperature conditions.

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

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

Coolant Solution It should be suitable for the ambient temperature and contain a minimum of 50% ethylene glycol solution.

See “Fluids and Lubricants” in the “Lubrication/Filters/Fluids” Section.

Engine Preheat Check the message display screen. The engine preheat indicator will show that the engine needs preheating and that the glow plugs are functioning.

T h e l e n g th o f t i me t h i s m e s s a g e r e m a i n s i s dependent on the coolant temperature. As soon as the engine reaches starting temperature, the audible alarm will sound.

4-10

OPERATING THE MACHINE IN HOT WEATHER During hot weather: 1. Keep the coolant at the correct level in the coolant reservoir and in the radiator.

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

3. Have the radiator cap tested 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 when operating in extremely dusty conditions.

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

CHAPTER 4 - OPERATING INSTRUCTIONS STOPPING THE ENGINE

CT06M012

Figure 5

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

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

NOTICE: If the engine is hot, let the engine run for about five minutes at idle speed to cool the turbocharger.

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

NOTICE: To activate the anti-theft device when stopping the engine, see “Anti-theft Device.”

CT06K024

Figure 6

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

The switch must be reset after use or engine will not restart.

NOTICE: If the engine is hot, let the engine run for about five minutes at idle speed to cool the turbocharger.

4-11

CHAPTER 4 - OPERATING INSTRUCTIONS

MACHINE TRAVEL WARNING Controls can be reversed!

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 upper structure. If the upper structure is turned 180 degrees in relation to the undercarriage, the controls are reversed.

Failure to comply could result in death or serious injury.

W0289A

Before undertaking any travel, raise the attachment.

NOTICE: Travel speed depends on the tilting angle of the travel control levers and pedals and the speed travel mode selected.

NOTICE: The following travel configurations described are with the travel reduction gears to the rear of the upper structure.

Traveling In A Straight Line (Forward)

GCS98M546

Traveling In A Straight Line (In Reverse)

Figure 7

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

BS00M167

Press the single travel pedal forward.

4-12

Figure 8

CS98M547

Figure 9

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

BS00M168

Press the single travel pedal rearward.

Figure 10

CHAPTER 4 - OPERATING INSTRUCTIONS Turning To The Left (Forward)

CS98M548

Turning To The Left (In Reverse)

Figure 11

CS98M549

Figure 13

Press the right-hand pedal (or push the right-hand lever) forward.

Press the right-hand pedal (or pull the right-hand lever) rearward.

Turning To The Right (Forward)

Turning To The Right (In Reverse)

CS98M551

Figure 12

CS98M550

Figure 14

Press the left-hand pedal (or push the left-hand lever) forward.

Press the left-hand pedal (or pull the left-hand lever) rearward.

Turning On The Spot, To The Right

Turning On The Spot, To The Left

CS98M552

Figure 15

Press the left-hand pedal (or push the left-hand lever) forward and at the same time press the right-hand pedal (or pull the right-hand lever) rearward.

CS98M553

Figure 16

Press the right-hand pedal (or push the right-hand lever) forward and at the same time press the left-hand pedal (or pull the left-hand lever) rearward.

4-13

CHAPTER 4 - OPERATING INSTRUCTIONS Gradual Turn On The Move

CS98M545

Figure 17

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.

Coming To A Stop To come to a complete stop, simply release the levers or pedals and they will return to neutral.

4-14

CHAPTER 4 - OPERATING INSTRUCTIONS LIFTING LOADS WITH THE MACHINE

WARNING This machine is not a crane. Use extreme caution when lifting loads. You or others in the area can be injured or killed if you do not operate the machine correctly. Failure to comply could result in death or serious injury.

This machine is not a crane. Be very careful when you lift a load.

Lifting capacities: See the lifting chart in the cab of your machine.

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

• Do not exceed either the radius or the height restrictions shown on the lift capacity charts posted in the cab or in this manual.

• Be careful to balance the load correctly.

• It is extremely dangerous if the load lifted begins to swing. The upper structure should be centered over the load to help prevent dangerous swinging.

• Always move the load slowly. Do not move the load over the top of persons. Keep all persons away from the load.

• When the load is raised, keep all persons away

until the load is placed on blocks or on the ground.

Figure 18

BD02D152

LOAD LIFTING CHART IN CAB

The load handling chart (located in the cab) shows the different permitted loads which can be lifted, depending on the reach and the type of attachment on the machine.

The machine must be on a flat, level, hard surface.

• Only the load lift eye on the bucket may be used.

• If this excavator is to be used to lift loads, for safety

purposes, it is recommended that the machine is properly equipped. Contact your Case dealer and install a Hose Burst Check Valve on your machine’s boom cylinders. This system prevents the sudden lowering of the load in the event of a failure of a hydraulic hose, line, or fitting in the boom hydraulic system. Such a failure can cause personal injury or death.

BD00J053

Figure 19

LOAD LIFT POINT ON BUCKET - ATTACH RIGGING HERE

• Know and understand each signal from the signal person before you start.

• Always know the location of all persons in your work area before you start.

• Make certain there is no damage to the lifting device and rigging parts.

• Make certain the lifting device has the appropriate tensile strength for the load being lifted.

4-15

CHAPTER 4 - OPERATING INSTRUCTIONS QUICK COUPLER (OPTIONAL) When load handling, always park the machine on a flat, firm surface.

Use slings and chains which are suitable for lifting the load to be handled and that are in optimum condition. Use safety hooks that will not accidentally open.

Check that machine safety valves function correctly. the pressure setting should be checked every six months. Consult your authorized dealer.

Place the overload indicator switch in the ON position.

Select the H work mode. See the right hand control arm in section 3.

CT02J046

Figure 20

Extend the bucket cylinder rod completely when using the quick coupler for load handling work.

Do not allow anyone within the machines operating radius. Do not lift loads over personnel or other equipment.

Operate the controls smoothly. Stabilize the load slightly above the ground to make certain it is well balanced.

Traveling with a load The upper structure should be in line with the undercarriage.

Keep the load as close as possible to the under carriage and to the ground.

Travel in low speed only.

BD00J053

Figure 21

The handling eye must be able to be seen from the operator’s compartment throughout the load handling operation. Do not use the front or rear fixing points of the quick coupler to handle any load.

Always consult the load handling char t in the machine to make certain you are within load handling limits.

4-16

CHAPTER 4 - OPERATING INSTRUCTIONS AUXILIARY HYDRAULIC CIRCUITS The machine has two types of auxiliary hydraulic circuits. One circuit is for single flow equipment, such as hydraulic breakers. The second type of circuit is designed for double flow use.

A H SP

1

Contact your Case Dealer to select the optional accessory compatible with your machine and to correctly adjust the flow requirement for its use.

H Y D R AU L I C B R E A K E R O R S I N G L E F L OW HYDRAULIC CONFIGURATION

CT06K086

Figure 24

Each time the switch is pressed, one of the different types of flows recorded for the pump can be selected. The icon of the accessory associated with each type of flow appears on the screen.

Figure 22

CT06K067

Using a hexagonal wrench, open the supply valves.

1

CT06K083

2

Figure 23

Toggle the switch (1) located on the right hand console downward, corresponding to the hydraulic breaker.

Make sure that the switch (2) is in the OFF position corresponding to a single flow hydraulic circuit.

In normal working position (digging) the switch (2) must be in the OFF positions.

4-17

CHAPTER 4 - OPERATING INSTRUCTIONS CHANGING THE FLOW PATTERN

2 1 567

2

AUTO

n n/min

H

E

F

4 3 Figure 28

CT06K026

Figure 25

CT06K083

1. Press the rocker switch on the console to display the flow pattern (1).

A H SP

1

4. Use the control switch on the right side console to select patterns. The wiper switch (2) will show the previous pattern. The auto idling switch (3) will show the next pattern. Use the travel mode change switch (4) to complete the change to the selected pattern.

NOTICE: Make certain to select the correct attachment, as the flow rate will be delivered according to pattern selected.

PUMP PATTERN FLOW RATES NOTICE: During machine operation, the flow rate will appear on the screen.

CT06K086

Figure 26

2. The registered pattern will be shown on the number next to the attachment icon.

Pattern

Flow rate per minute

Values

1 Pump Flow

2 Pump Flow

A

34.0 gal. (129 L)

68.2 gal.(258 L)

B

31.4 gal. (119 L)

65.5 gal. (248 L)

1

28.0 gal. (106 L)

62.0 gal. (235 L)

C

26.4 gal. (100 L)

60.5 gal. (229 L)

2

23.0 gal. (87 L)

57.0 gal (216 L)

Figure 27

D

19.8 gal. (75 L)

53.9 gal. (204 L)

3. By continuing to press the switch for 3 seconds a flow rate screen will appear on the monitor.

3

16.9 gal. (64 L)

51.0 gal. (193 L)

E

14 gal. (53 L)

48.0 gal. (182 L)

F

10.3 gal. (39 L)

44.4 gal. (168 L)

G

9.2 gal. (35 L)

43.3 gal. (164 L)

BS07B127

4-18

CHAPTER 4 - OPERATING INSTRUCTIONS OPTIONAL JOYSTICK CONFIGURATION

1 1 5

3

4 6

Figure 29

CT06K024B

LEFT HAND JOYSTICK

The left hand joystick can control four machine operations for the operator’s convenience. The radio mute switch is located on the underneath side of the joystick, while button (3) enables the horn. Two additional function switches (1) and (2) are available for optional use.

The right hand joystick controls the engine idle speed selector (6). This button enables automatic engine idle without operating the throttle button. To select idle speed, press and release the control for the engine automatically to go into idle speed. The message “Eng. Idling” will appear on the monitor display panel. When the control is pressed and released once more the engine will rever t to its original speed and the message on the monitor display panel will disappear.

The two additional buttons (4) and (5) on the right hand joystick are for optional tools such as a hydraulic hammer, breakers, or other special attachments.

Figure 30

CT06K022B

RIGHT HAND JOYSTICK

The switches can be wired by your Case Dealer to control either single function or dual function hydraulic configurations.

The machine can have two types of auxiliar y hydraulic circuits. One circuit can be used for single flow equipment, such as hydraulic breakers. The second type of circuit is intended for use with single flow or double flow (with continuous flow) for use with demolition concrete crushers, etc.

The optional control buttons can be used to activate and control the system for multipurpose tools such as a crusher, nibbler, etc. Additionally they can be configured to regulate the preset hydraulic oil flow for the specific tool when pressed.

See your Case Dealer for specific options and controls for hydraulic hammers, breakers, nibblers, or other special attachments.

4-19

CHAPTER 4 - OPERATING INSTRUCTIONS OPERATING THE MACHINE IN WATER

Figure 31

CS99A825

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

2. Only the undercarriage may 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.

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

OPERATING THE MACHINE ON SLOPING GROUND\

WARNING Driving hazard!

Hillside operations can be dangerous. Rain, snow, ice, loose gravel, or soft ground, etc. can change the ground conditions. You must make a judgment if it is safe to operate your machine on any hillside or ramp.

Failure to comply could result in death or serious injury.

W0144A

• Use extreme caution on hillside operations.

• Make sure the upper structure swing is in locked position, and that low travel speed is selected.

• When digging on a slope, avoid swinging the

upper structure towards the bottom of the slope with the bucket full. Always keep the travel reduction gears pointing down towards the bottom of the slope.

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

4-20

CHAPTER 4 - OPERATING INSTRUCTIONS OPERATING THE BUCKET Filling Maneuver the arm to fill the bucket. Keep the bottom of the bucket parallel to the cut. The 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

Figure 32

PDH0494M

Figure 33

CORRECT

WRONG

WRONG

The bucket will dig in and cause a stall.

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

4-21

CHAPTER 4 - OPERATING INSTRUCTIONS PARKING THE MACHINE 1. Place the machine on flat, level ground, away from soft ground excavations and any shored cavities.

2. Place the upper structure frame in line with the undercarriage, retract the attachment and dig the bucket into the ground to anchor it.

Figure 36

CT06M029

5. Raise the function cancellation lever (safety bar to the inward position).

CD00E010

Figure 34

3. Turn the engine throttle button to low idle position and let the engine run for approximately one minute. If necessary, activate the anti-theft device.

Figure 37

CT06K017

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

WARNING CT06M022

Figure 35

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

Fall hazard!

Jumping on or off the machine could cause an injury. Always face the machine, use the handrails and steps, and get on or off slowly. Maintain a three-point contact to avoid falling: both hands on the handrails and one foot on the step, or one hand on the handrail and both feet on the steps.

Failure to comply could result in death or serious injury.

W0141A

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

4-22

CHAPTER 4 - OPERATING INSTRUCTIONS TOWING THE MACHINE Before attempting to tow the machine, consult your CASE Dealer.

Wherever possible, carry out any repairs at the site. The machine must be towed very slowly, over a short distance, and only if it is unavoidable.

WARNING Towing is a delicate maneuver that is always carried out at the risk of the user. The manufacturer's warranty does not apply to incidents or accidents that occur during towing. Where possible, carry out the repairs at the site.

Failure to comply could result in death or serious injury.

WARNING Hazard to bystanders!

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.

Failure to comply could result in death or serious injury.

W0259A

LOWERING THE ATTACHMENT IN THE EVENT OF MACHINE FAILURE If the engine breaks down, use the following procedure to lower the attachment:

CT06M021

Figure 38

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

CT06K030

2. Lower the function cancellation lever (safety bar in outward position).

CT06K082

Figure 40

3. Place the control lever(s) in the position corresponding to the downward movement required.

Figure 39

4-23

CHAPTER 4 - OPERATING INSTRUCTIONS

TRANSPORTING THE MACHINE SETTING THE 3.0 M DIPPER INTO THE TRANSPORT POSITION (IF EQUIPPED)

CT02C200

Figure 41

1. Extend the boom and dipper and place the attachment tool on the ground, as shown.

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

CT02C202

Figure 43

7. Grease the linkage.

8. Install the cylinder rod pin and secure in place with the pin attachment.

3. Support the dipper cylinder using appropriate lifting equipment.

CT02C203

CT02C201

Figure 42

4. Remove the pin attachment and drive out the cylinder rod pin.

Figure 44

IMPORTANT: In this configuration, the working range of the dipper allows the tool to interfere with the machine. Operate with great care when putting the machine into position for transport.

5. Start up the engine, retract the dipper cylinder rod as far as possible to move the cylinder rod eye into transport position.

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

CT02C201

Figure 45

IMPORTANT: After machine transport, you must move the dipper cylinder into the working position.

4-24

CHAPTER 4 - OPERATING INSTRUCTIONS

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

ON A TRAILER

WARNING Transport hazard!

The machine can slip or fall from a ramp or trailer. Make sure the ramp and trailer are not slippery. Remove all oil, grease, ice, etc. Move the machine on or off the trailer with machine centered on the trailer or ramp.

Failure to comply could result in death or serious injury.

W0152A

WARNING Tip-over hazard!

The counterweight MUST be removed before transporting the machine without an attachment. Consult you dealer.

Failure to comply could result in death or serious injury.

W0260A

Follow all safety rules and regulations before transporting the machine. Make certain both trailer and machine are fitted with the right safety equipment. Load binders should be of sufficient capacity and in good condition.

Loading

v

!4567

2

AUTO

n n/min

H

E

F

2 1 CD00E010 CD95M248

Figure 46

1. Keep all unauthorized personnel clear of the area. Place a block behind the trailer wheels.

Install the trailer side extensions (if fitted).

Figure 47

2. Select the automatic engine idle function (1).

Select low travel speed, the indicator lamp to the left of travel speed selector will not be illuminated.

4-25

CHAPTER 4 - OPERATING INSTRUCTIONS Machine with Attachment

PDH0248

Figure 48

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

Raise the attachment and bring it about 7-8 inches (20 cm) above the bed of the trailer.

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

4-26

PDH0250

Figure 49

When the machine is completely and safely on the trailer, swing the upper structure to bring the attachment toward the ramp end. Bring the machine itself to the front of the trailer. Use blocks and chains to fasten the machine and attachment to the trailer.

CHAPTER 4 - OPERATING INSTRUCTIONS Machine without Attachment

CS99B518 CD00E150

Figure 50

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

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

Figure 52

Use blocks and chains to fasten the machine to the trailer. Load binders should be in good condition and of sufficient capacity and strength NOTICE: 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.

Unloading 1. Keep all unauthorized personnel clear of the area.

Remove the blocks and fastening chains.

2. Fasten your seat belt and start the engine.

3. Lower the function cancellation lever (with the safety bar in outward position).

4. Unlock the upper structure swing function.

CD00E150

Figure 51

Place the machine at the front of the trailer and swing the upper structure 180 degrees.

Stop the engine, remove the starter switch key, raise the function cancellation lever (with the safety bar inward).

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

Fold the rear view mirrors inwards. Retract the radio aerial, if equipped.

5. Select low travel speed and slowly move off the trailer.

6. Turn the rear view mirrors back to their correct position.

7. For machines without attachments, reinstall the arm, counterweight, and attachment.

8. When the attachment has been installed, all air must be removed from the hydraulic circuit and the mac hine s hould be tested for cor rec t operation. Check the hydraulic fluid level.

4-27

CHAPTER 4 - OPERATING INSTRUCTIONS

MACHINE STORAGE Preparation For Storage

Periodical Checks

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. If a building is not available, park the machine in a dry area on planks and use wheel chocks, front and rear. Cover the machine with a waterproof covering. Before s to r i ng t he ma c hi ne, c ar r y o ut t he fol l owi n g operations:

Every month, check: A. The electrolyte level in the batteries and the battery charge. Recharge the batteries if necessary.

B. The grease on the cylinder rods.

C. The fuel level in the fuel tank and the oil level in the engine. Add more fluids, if necessary.

1. Clean the machine completely and lubricate all components equipped with grease fittings.

D. The condition of all lines, connectors, and clamps (rust). Lubricate, if necessary.

2. Drain the water from the cooling system. If the system is filled with an antifreeze mixture, this operation is not necessary.

E. The condition of the paint. Apply a coat of anti-rust treatment where necessary.

3. To avoid rust, it is necessary to refill the fuel tank completely.

4. Crank the engine a few turns to spread a protective film on the cylinder walls.

5. If possible, store the batteries in a place where there is no danger of freezing. Recharge them monthly.

6. To insure adequate protection of the transmission components, at least once a month, t h e m a c h i n e s h o u l d b e m o ve d fo r s h o r t distances, so that a film of oil is renewed on the parts.

7. Place a Do Not Operate tag on the key switch or steering wheel.

Starting Up After Storage 1. Close the drain valves and fill 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. Lubricate 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 gear oil level and add more oil if necessary.

10. Clean the cylinder rods.

11. Remove the Do Not Operate tag and start the engine, following the starting up procedure.

12. Keep a careful watch on all systems display panel lamps and indicators.

WARNING Avoid injury!

Check the machine for leaks or for any parts that are broken, defective, or missing.

Failure to comply could result in death or serious injury.

4-28

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

Chapter 5 LUBRICATION, FILTERS, AND FLUIDS TABLE OF CONTENTS GENERAL SAFETY BEFORE YOU SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Releasing Pressure In The Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Bleeding Air From The Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Systemgard® Lubrication Analysis Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Engine Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 FLUIDS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Engine Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Hydraulic Reservoir/Transmission Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Travel Reduction Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Swing Reduction Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Engine Oil Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Oil Viscosity/Temperature Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Daily/Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 MACHINE AND ATTACHMENT LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 10 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 250 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 500 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35 2000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45 4000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48 5000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50

5-1

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

5-2

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

GENERAL SAFETY BEFORE YOU SERVICE WARNING

WARNING

Avoid injury!

Do not attempt to operate this machine unless you have first read and understand the safety messages and instructions appearing in this manual. Failure to comply could result in death or serious injury.

Pressurized system!

Before you begin any service or repair work you must know and understand how to relieve hydraulic pressure properly. Always have tools and attachments down in safe positions. Failure to comply could result in death or serious injury.

M1087

WARNING

WARNING

To help prevent personal injuries during operation and maintenance, use safety shoes, a hard hat, safety glasses or goggles and good fitting clothing.

Failure to comply could result in death or serious injury.

Improper operation or service of this machine can result in an accident.

If you do not understand a maintenance procedure, or doubt your ability to perform a maintenance procedure correctly, see your authorized dealer.

Failure to comply could result in death or serious injury.

Comply promptly with maintenance intervals by checking the hourmeter every day. Before starting maintenance, park the machine on firm, level ground, away f r o m a ny o b s t a c l e s wi th t h e bu cke t o r attachment on the ground. Keep all unauthorized personnel clear of the area. Unless otherwise specified, all maintenance operations should be carried out with:

• • • • • • •

the engine stopped the parking brake engaged the key removed from the starter switch a Do Not Operate tag placed on the key switch

W0157A

WARNING Pressurized system!

Before attempting any service procedure, it is your responsibility to know the number of accumulators on the machine, and the correct procedure for releasing the pressure of each accumulator.

Failure to comply could result in death or serious injury.

W0136A

all circuits cooled down before starting work all hydraulic pressure released any accumulator pressure released for the appropriate circuit

• all non-authorized personnel clear of the machine operating area

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.

Wear suitable clothing, and remember to use the necessary safety equipment.

NOTICE: The inspection and maintenance charts provided in this section give only general time intervals. It may be necessary to developed a custom schedule to perform machine maintenance at more frequent intervals based on the work conditions.

When carrying out service work on the machine, place a Do Not Operate or war ning tag on the instrument panel or key switch. 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.

The service intervals in this chapter refer to normal operating conditions. During the first operation period of a new machine or rebuilt component and/or under particularly severe conditions the service intervals should be carried out more frequently.

NOTICE: Oils and fluids must be disposed of properly. Be aware of environmental issues.

5-3

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS RELEASING PRESSURE IN THE HYDRAULIC SYSTEM NOTICE: Before carrying out any work on the hydraulic system, there should be no pressure in any of the circuits.

1. Keep all unauthorized personnel clear of the area. Park the machine on firm, level ground.

Lower the attachment to the ground, and stop the engine.

Figure 3

CD00E11

4. Operate the control levers from right to left and front to rear approximately a dozen times. Turn the starter key to the OFF position.

Figure 1

CT06M021

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

Figure 4

CD01N035

5. Unscrew the hydraulic reservoir protective cap and remove it.

breather

6. Press the button on top of the breather to release any residual pressure.

Figure 2

CT06K030

3. Lower the function cancellation lever (safety bar in outward position).

WARNING Pressurized system!

Make sure that there is no pressure in the hydraulic lines before checking or repairing.

Do not use defective hoses or fittings. Always replace worn or defective hoses or fittings. Failure to comply could result in death or serious injury.

5-4

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. Failure to comply could result in death or serious injury.

WARNING Touching hot surfaces could cause burns. The engine and components will be hot after the machine has been running. Allow the engine and components to cool before servicing the machine.

Failure to comply could result in death or serious injury.

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS BLEEDING AIR FROM THE HYDRAULIC COMPONENTS

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. Failure to comply could result in death or serious injury.

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

NOTICE: After bleeding air from the components, stop the engine for five minutes and check to make certain there are no bubbles at the surface of the hydraulic fluid in the reservoir.

Attachment Cylinders

BLEEDING AIR FROM THE HYDRAULIC COMPONENTS

Keep all non-authorized personnel clear of the area.

Start and run the engine at low idle speed. Extend and retract the attachment cylinder rods four or five times without bringing the cylinders to the end of the stroke. Then repeat the operation three or four times, this time bringing the cylinder rods to the end of stroke.

Hydraulic Pump

CT07K040

Figure 5

Keep all unauthorized personnel clear of the area.

Clean around the air bleed plug. Loosen the air bleed plug, remove the plug if the fluid does not flow.

Fill the pump with hydraulic fluid through this port until the fluid comes up to the edge of the port. Install and tighten the air bleed plug.

Start the engine and run it 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.

Bleed the second bleed plug hole at the same time.

5-5

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS HYDRAULIC SWING REDUCTION GEAR

CD01N028

Figure 6

Keep all non-authorized personnel clear of the machine. Start and run the engine at low idle speed.

Loosen the unions on the top of the swing motors to release any air.

Retighten the unions as soon as the fluid flows out of the ports.

After the warm up procedure is completed, move each control slowly several times to remove any air in the system.

Swing the upper structure evenly left to right two complete turns or more.

Stop the engine, and wait five minutes.

Check the oil level in the hydraulic reservoir, and add oil as required. Be certain there are no air bubbles in the hydraulic reservoir.

5-6

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS SYSTEMGARD® LUBRICATION ANALYSIS PROGRAM

ENGINE HOURMETER Service your machine at the intervals and locations g i ve n i n t h e Q u i c k R e fe r e n c e L u b r i c a t i o n Maintenance Chart. When you service your machine, use only high quality lubricants.

TRIP

ODO

12345.6

1/10H

AUTO

n n/min

A27274

Figure 7

Ask your dealer about our lubr icant analysis program, Systemgard®. Through this service, your lubricants are tested in an independent laboratory.

You simply remove a sample of lubricant from your machine and send the sample to the independent Sy stemgar d ® la bora tor y. After the s ampl e is processed, the laboratory will report back to you and guide you with maintenance requirements.

Systemgard® can help support your equipment up time and provide you with a service that can pay back dividends when you trade for another piece of equipment.

CT06M013

TRIP

Figure 8

The engine hourmeter shows the amount of actual hours the engine has run. The first number to the right displays tenths of an hour and the numbers to the left display hours. Use the engine hourmeter along with the Lubrication/Maintenance Chart to service your machine at the correct time periods.

Engine hours are displayed with the key switch off or with the engine running.

The normal engine oil change interval is every 500 hours of operation. Operating conditions, quality of the engine oil and sulphur content of the fuel can change this interval. It is recommended that you use the Systemgard® Lubricant Analysis program. See your dealer.

PLASTIC AND RESIN PARTS Avoid using gasoline, kerosene, paint thinner, etc., when cleaning plastic windows, console, instrument cluster, monitor, gauges, etc. Use ONLY water, mild soap and a soft cloth when you clean these parts.

Using gasoline, kerosene, thinners, etc., will cause discoloration, cracking or deformation of the part being cleaned.

5-7

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

FLUIDS AND LUBRICANTS ENGINE CRANKCASE Capacity with Filter Change ....................................................................................................... 18 Qts. (17 Liters) Specifications ...................................................................................................................... CASE AKCELA No. 1 FUEL TANK Capacity ................................................................................................................................68.7 gal. (260 Liters) COOLING SYSTEM Capacity .............................................................................................................................. 15.4 Qts. (14.6 Liters) Specifications ............................................................................................. 50% Water and 50% Ethylene Glycol NOTE: If the ambient temperature is lower than -37°C (-34°F), adjust the mixture according to the coolant manufacturer specifications.

HYDRAULIC RESERVOIR/TRANSMISSION REFILL Total system capacity .............................................................................................................41.5 gal. (157 Liters) Reservoir capacity.................................................................................................................... 21.7 gal. (82 Liters) Specifications ................................................................................................................................ Hy-Tran® Ultra TRAVEL REDUCTION GEARS Capacity - (per reduction gear) ................................................................................................ 2.2 Qts. (2.1 Liters) Specifications ................................................................................................................................. Case 135 H EP SWING REDUCTION GEARS Capacity (per reduction gear)................................................................................................... 2.3 Qts. (2.2 Liters) Specifications ............................................................................................................................... Case 135 H EP TURN TABLE TEETH Capacity .......................................................................................................................................... 21.8 lb (9.9 kg) Specifications ................................................................................................................................. Case 251 H EP

5-8

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

ENGINE LUBRICATION ENGINE OIL SELECTION API Service CI-4 Engine Oil is recommended for use in your Case Engine. Case AKCELA No. 1 Engine Oil will lubricate your engine correctly under all operating conditions.

If Case oil is not available, use only oil meeting API engine oil standards.

NOTICE: The use of low viscosity oils, such as 10W-30 can be used to aid in starting the engine and in providing sufficient oil flow at ambient temperatures below -5°C (23°F). The continuous use of low viscosity oils can decrease engine life due to wear. See the chart below for the correct oil for ambient temperatures.

See the chart below for recommended viscosity at ambient air temperature ranges.

NOTICE: Do not put performance additives or other oil additive products in the engine crankcase. The oil change intervals given in this manual are according to tests with Case lubricants.

NOTICE: Use of an engine oil pan heater or an engine coolant heater may be required when operating in Winter or Arctic conditions.

BD97F136

Figure 9

OIL VISCOSITY/TEMPERATURE RANGES

BC02N250

Figure 10

5-9

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS FLUIDS AND LUBRICANTS Lubricants must have the correct properties for each application. Adhere to machine lubrication intervals specified by the manufacturer.

TRANSMISSION COMPONENT OIL

HYDRAULIC FLUID

CASE/AKCELA: GEAR 135H EP

CASE/AKCELA 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.

Temperate Climates -20°C to +40°C CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID (MAT 3509 ISO VG 46. DIN 51524 PART 2 HV) Hot Climates 0°C to +50°C CASE/AKCELA: AW HYDRAULIC FLUID 68 HV ( M AT 3 5 0 8 I S O VG 6 8 . D I N 5 1 5 2 4 PA RT 3 CATEGORY HVLP) Cold Climates -25°C to +20°C CASE/AKCELA: AW HYDRAULIC FLUID 32 (MAT 3508 ISO VG 32. DIN 51524 PART 2) Biodegradable Fluid: -30°C to +40°C This yellow-colored fluid is miscible with standard fluid. If used to change standard fluid, it is advisable to drain the circuit completely before refilling with this fluid.

CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID BIO (MAT 3509 ISO VG 46. DIN 51524 PART 2 HV)

5-10

Extreme pressure oil used for enclosed transmission components.

(SAE 80W-90. API GL 5. MIL-L-2105 D. MAT 3506 ZF TE-ML 05A) GREASE CASE/AKCELA: MAT 3550 MOLY GREASE 251H EP-M (NLGI 2) “Extreme Pressure” multipurpose grease with lithium soap and molybdenum dissuasively.

CA S E /A K CE L A: MAT 3 55 0 M ULT IP UR PO SE GREASE 251H EP (NLGI 2) “Extreme Pressure” multipurpose grease with lithium soap and calcium.

CASE/AKCELA: MAT 3550 PREMIUM GREASE EP2 (NLGI 2) “Extreme Pressure” multipurpose grease with lithium soap.

Hydraulic Breakers C ASE/ A K C E L A : M AT 3 5 5 0 M U LT IPU R POS E GREASE 251H EP (NLGI 2).

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS Coolant Solution Put only ethylene-glycol coolant solution in the cooling system. Use good quality ethylene-glycol that has a high boiling point with no additives to prevent l e a k a g e. D o n o t u s e n o n - a p p r o ve d a n ti - r u s t additives. Anti-rust additives and ethylene-glycol can m i x a n d w o r k a g a i n s t e a c h o t h e r, r e d u c i n g anti-corrosion protection, forming deposits in the cooling system, and causing damage to the cooling system and radiator. Contact your dealer who can supply you with the suitable coolant solution.

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

For areas where the ambient temperature is over -36°C (-34°F), use a blend of 50% ethylene-glycol based anti-freeze.

For areas where the temperature is below -36°C (-34°F), it is advisable to use a blend of 40% water and 60% anti-freeze.

HYDRAULIC FLUID Use hydraulic fluid specifically designed for high pressure applications. Your dealer can provide hydraulic fluid to fulfill different climate/temperature conditions.

TRANSMISSION COMPONENT OIL Extreme pressure oil should be used for enclosed transmission components. Choose an oil that is m a n u fa c t u r e d fo r yo u r c l i m a t e / t e m p e r a t u r e conditions.

GREASE The type of grease to use depends on ambient tem pera ture. Use a q uality extrem e pressu re multipurpose No. 2 grease.

ENGINE OIL CI-4 is recommended for your engine. This oil insures correct lubrication of your engine in all working conditions.

2. Do not mix either type of BIO OIL with the original factory filled mineral oil. If BIO OIL is used, flush the hydraulic system that was filled with mineral oil twice. This is a requirement before adding bio oil.

3. If you use BIO OIL, swing and propel parking brake performance will be reduced, because of the lower friction of BIO OIL compared to that mineral oil.

4. For further information about recommended Bio-degradable oil, please contact local dealer.

ENVIRONMENT Before you service this machine and dispose of oil, fl ui ds, an d lu br i c an ts, a l way s rem e m ber th e environment. Do not drain oil or fluids on to the ground or into containers that leak. Check with your local environmental, recycling center or your dealer for correct disposal information.

FUEL NOTICE: Use diesel fuel suitable for the ambient temperature conditions (ASTM-D-975).

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

Use grade No. 2 fuel. The use of other types of fuel can result in a loss of power of the engine and may cause high fuel consumption.

In cold weather, it is tentatively approved to use a mixture of fuels No. 1 and No. 2. Consult your fuel supplier.

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.

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

FUEL STORAGE

NOTICE: 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 with approved lubricants.

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

USE OF BIO-DEGRADABLE OILS

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.

When using Bio-degradable Oil (BIO OIL), refer to the following information: 1. There are two types of BIO OIL available; vegetable based and synthetic based. Synthetic based type is recommended, as the vegetable based oil has a maximum usage temperature of 80°C (176°F). The degradation of vegetable based oil occurs more rapidly and causes reduced service life.

5-11

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS BIODIESEL FUEL Fatty Acid Methyl Ester Biodiesel (Biodiesel Fuel) consists of a family of fuels derived from vegetable oils treated with methyl esters.

NOTICE: Biodiesel fuel blends are approved for your engine only if they comply with Specification Standards EN 14214 or ASTM D6751. Do not use biodiesel unless it is approved for your engine.

Check with your authorized dealer for information.

It is imperative that you check which blend is approved for your engine with your local dealer.

Beware that the use of Biodiesel fuel that does not comply with the Standards EN14214 or ASTM D6751 could lead to severe damage to the engine and fuel system of your machine. The use of fuels that are not approved may void warranty coverage.

Biodiesel Fuel Usage Conditions NOTICE: The Biodiesel Fuel must meet the fuel specification mentioned above.

Biodiesel fuel must be purchased from a trusted supplier that understands the product and maintains good fuel quality. Biodiesel fuel must be pre-blended by the supplier. Mixing Biodiesel fuels on site can result in an incorrect mixture which can lead to problems with both engine and fuel system.

When handling biodiesel fuel, care must be taken not to allow water into the fuel supply. Biodiesel fuel will actually attract moisture from the atmosphere. Fuel tanks must be kept as full as possible to limit the amount of air and water vapors in them. It may be necessary to drain the fuel filter water tap more frequently.

Potential oxidation and stability could be a problem with the fuel store in the machine.

Biodiesel fuel may degrade natural rubber gaskets and hoses, as it is more solvent than petro-diesel.

Check hoses and other engine components more frequently when using a biodiesel fuel.

DO NOT allow water to collect in the fuel or storage tanks. Biodiesel will actually attract moisture from the atmosphere. Keep fuel tanks and storage tanks as full as possible to limit the amount of air and water vapors. It may be necessary to drain the machine fuel filter more frequently. Potential oxidation and stability could create a problem with fuel stored in the machine.

BIODIESEL STORAGE NOTICE: DO NOT store machines for more than three months with biodiesel blends in the fuel system. DO NOT store biodiesel fuel in on-site storage tanks for more than three months.

Engine perfor mance is effected by the use of biodiesel fuel. There may be up to 12 percent reduction in power or torque depending on the blend used.

If long periods of storage are required, run the machine for 20 hours using regular diesel fuel in order to flush the biodiesel fuel from the engine fuel system.

NOTICE: DO NOT modify the engine and/or fuel injection pump settings to recover reduced performance.

NOTICE: Biodiesel fuel must not be stored in on-site storage tanks for more than 3 months.

Any spillage of biodiesel fuel must be cleaned up immediately before it can cause damage to the environment and/or the paint finish of the machine.

Before using biodiesel fuel blends, you should consult with your dealer to receive full information about the approved blend for your machine and any detailed conditions of its usage.

The reduced power must be accepted if using any biodiesel fuel blend.

Some modification may be required to allow the engine to use biodiesel fuel. Consult your dealer for c o m p l e t e i n fo r m a t i o n r e g a r d i n g a p p r o v e d modifications.

Biodiesel has a higher cloud point than diesel fuel.

NOTICE: The use of high biodiesel fuel blends is not recommended in cold weather conditions.

With biodiesel fuels, it may be necessary to change engine oil, engine oil filters and fuel filter elements more frequently then with diesel fuel. Biodiesel can remove rust and other particles that adhere to the inside of the fuel tank. These particles are then trap ped by the ve hicle filters and may cause shortened filter life and/or filter blockages. In cold weather, this is more likely to occur. Consult your dealer for information on cold weather operation and proper maintenance inter vals when using any biodiesel fuel blend.

5-12

Be aware that not fulfilling the requirements and conditions of biodiesel fuel usage will void your machine’s warranty.

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART

As Required (AR)

Every 10 hours

Every 50 hours

Every 250 hours

DRAIN

GREASE

REPLACE

CHECK

CLEAN

PAGE

SERVICE POINTS

INITIAL NEW MACHINE

Intervals In Hours SERVICE INTERVALS

6-14

Fan and air conditioning drive belt

AR

5-39

Air filter

AR

AR

6-8

Fuel tank screen

AR

AR

6-3

Clean track

6-5

Steel track shoe bolt torque

AR

5-24

Engine oil level

10

5-24

Coolant level

10

5-25

Radiator and oil cooler

10

5-25

Fan/alternator belt tension

10

5-26

Hydraulic reservoir level

10

5-27

Bleed fuel prefilter

10

5-27

Bleed fuel filter

10

5-28

Hydraulic system lines

50

6-14

Air conditioning

50

6-5

Track shoe bolt torque

Run-in

50

6-18

Bolt and nut torque

Run-in

50

7-4

Battery check

5-29

Pilot filter

5-29

Drain hydraulic reservoir sediment

5-30

Return filter

Run-in

250

5-31

Swing reduction gear

Run-in

250

5-32

Travel reduction gears

Run-in

250

5-33

Fuel prefilter

5-34

Air Filter dust ejector

5-16

Grease attachment

6-5

Track shoe bolt torque

250

6-18

Bolt and nut torque

250

7-5

Battery electrolyte level

250

6-7

Fan/Alternator belt tension

250

6-5

Idler wheel and roller

250

AR

50 Run-in

250 250

250 250 250

5-13

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

Every 500 hours

Every 1000 hours

Every 4000 hours

Every 5000 hours

Machine grease points

500

5-35

Turntable bearing

500

5-35

Turntable teeth

500

5-36

Engine oil

500

5-36

Engine oil filters

500

5-37

Fuel filter

500

5-38

Priming pump

5-16

Machine arm and attachments

5-39

Air filter primary and secondary

5-41

Hydraulic fluid condition

5-42

Swing gear

1000

5-43

Breather filter

1000

5-44

Travel reduction gear

500 1000 1000 1000

1000

Tappet clearances

1000

Alternator

1000

Starter motor

1000

5-45

Inlet filter

5-46

Return filter

2000

5-47

Pilot filter

2000

5-47

Swing reduction gear

5-47

Fuel tank

5-48

Draining and filling cooling system

2000

2000 2000 2000

Fuel hoses

4000

Main pump output hydraulic hoses

4000

Boom/bucket cylinder hydraulic hoses

4000

5-50

Hydraulic fluid

5000

5-51

Replacing inlet filter

5000

See your Case Dealer

DRAIN

GREASE

REPLACE

CHECK

5-16

See your Case Dealer

Every 2000 hours

CLEAN

PAGE

SERVICE POINTS

INITIAL NEW MACHINE

Intervals In Hours SERVICE INTERVALS

RUN-IN: Maintenance items designated as run-in are for initial fluid or filter changes for a new or rebuilt machine.

Follow the regular maintenance intervals as indicated thereafter for best machine performance.

NOTICE: Due to operating conditions, the service intervals may need to be shortened to provide maximum machine performance and protection.

NOTICE: Once the machine has completed 500 hours (then 1000 hours, 1500 hours, etc.) the message Service Due will appear on the screen by way of a reminder that service work is due. See “Systems Display and Control Panel” in the “Controls/Instruments/Accessories” Section.

5-14

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS DAILY/PERIODIC INSPECTION Every day, before starting work, it is necessary to inspect the machine and service certain of its components.

General

• • • •

Check for signs of leaking oil or water.

Check that all screws and nuts are correctly tightened.

Wipe off any dust (engine, operator’s compartment, decals and warning labels).

Check for any signs of deterioration.

Engine

• • • • • • •

Check the oil level, and change the oil if necessary.

Check the coolant level.

Check the radiator for signs of clogging or deterioration of air flow.

Check the radiator fan belt tension.

Check the air filter for cleanliness and/or restrictions.

Check the components for signs of leaking oil or water.

Check the condition of all lines and tubes.

Upper Structure

• • • • • • • •

Check the fuel tank level.

Check the hydraulic reservoir level.

Check that the hydraulic oil is clean.

Check the components for signs of leaking oil or water.

Check the condition of all lines.

Make sure there are no electrical short circuits.

Check the battery connections are properly tightened.

Adjust the rear view mirrors.

Undercarriage

• Check the pad and pad hardware.

• Check the condition of the track chain assembly.

• Check that the upper and lower track rollers and the idler wheels are not leaking oil.

Attachment

• • • •

Check the cylinders are not leaking oil.

Check the condition of all lines and tubes.

Check the condition of the bucket teeth.

Check the attachment for any damage or deterioration.

After Starting The Engine

• • • • • •

Did the engine start correctly? Are the exhaust fumes normal? Any strange noises?

Check that the hydraulic components are not making strange noises.

Check the components for signs of leaking oil or water.

Check the audible alarm devices, working lights and windshield wipers.

Check that all circuits (travel, swing and tool) are functioning correctly.

Check that the upper structure swing brake functions correctly.

NOTICE: If any maintenance issue is found, place a Do Not Operate tag on the key switch, and repair it immediately prior to using the machine or contact your dealer.

5-15

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

MACHINE AND ATTACHMENT LUBRICATION GREASE POINTS Type of grease ..................................................................................................................See "Fluids and lubricants" NOTICE: The numbers within brackets indicate the number of lubrication points.

After lubrication, refit the grease fitting protective caps.

MACHINE

C D

A

B

CT07K012

Every 50 hours Dozer blade (if equipped) ....................................... (2)

A

Dozer blade cylinders (if equipped)......................... (4)

CT07K011

5-16

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS Every 500 hours Turntable................................................................... (2)

B

CT07K031

Turntable teeth ......................................................... (1) See "Greasing the Turntable Teeth".

C

CT07K031

Every 2000 hours Swing reduction gear .............................................. (1)

D

See "Greasing the Swing Reduction Gear".

CT07K032

5-17

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS ATTACHMENT Monobloc boom/arm

A

A

C

B

CT07K013

NOTICE: If the following linkage points are not equipped with original parts, these points must be lubricated every 50 hours.

Every 1000 hours Boom bottom pin ...................................................... (2) Boom cylinder top pin............................................... (2) Dipper cylinder bottom pin........................................ (1)

A

CT07A077

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

B

CT07K033

5-18

D

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS Boom/dipper linkage................................................. (2)

C

CT06M023

Dipper cylinder top pin.............................................. (1)

D

CD01N023

5-19

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS Arm/backhoe bucket

C B

A CT07K013

NOTICE: If the following linkage points are not equipped with original parts, these points must be lubricated every 10 hours.

Every 250 hours Bucket linkages......................................................... (2)

A

CD00E054A

NOTICE: If the following linkage points are not equipped with original parts, these points must be lubricated every 50 hours.

Every 1000 hours Yoke/connecting rod linkages................................... (4)

B

CD00A054A

5-20

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS Bucket cylinder bottom pin ....................................... (1)

C

CT06K094

5-21

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS QUICK COUPLER TOOL LUBRICATION (optional) Every 50 hours Cylinder bottom pin................................................... (1) Locking system pivot ................................................ (1)

CT02D344

Cylinder top............................................................... (1)

CT02D345

Hook pivot ................................................................. (1)

CT02D346

5-22

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS GREASING THE TURNTABLE TEETH Grease capacity...................................................................................................................................9.9 kg (21.9 lb) Type of grease .................................................................................................................See "Fluids and Lubricants" Every 500 hours 1.

Remove the inspection cover (1) and visually check the condition of the gear surface and for any damage.

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.

1

CT07K031

4.

-

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

Remove the protective panel from the lower central area.

Remove plug (2).

Discharge the water or contaminated grease.

Install plug (2).

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

2

CD01K028

GREASING THE SWING REDUCTION GEAR Grease capacity................................................................................................................................. 0.3 kg (10.6 Oz) Type of grease .................................................................................................................See "Fluids and Lubricants" Every 2000 hours Remove the lower panel, remove the air bleed plug (1) and refill with grease through the grease point (2). A certain amount of grease should run out from the air bleed plug (1).

Install the air bleed plug (1) then install the lower panel. aLWAYS REMOVE THE AIR BLEED PLUG When greasing. The inner seal will be damaged if the air bleed plug (1) is not removed.

2

1 CT07K032

5-23

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 10 HOUR MAINTENANCE ENGINE OIL LEVEL

CHECK COOLANT LEVEL

Perform the following procedures daily or at every ten hour shift.

Service Specifications System capacity . . . . . . . . . . . 15.4 Qts (14.6 Liters)

Service Specifications Oil Type. . . . . . . . . . . . . . . . . . CASE AKCELA No. 1 Oil Capacity with filter . . . . . . . . . . 18 Qts. (17 Liters)

Check the coolant level before you start the engine each day or before the start of each 10 hour shift.

Check the engine oil level before you start the engine each day or before the start of each 10 hour shift.

Always check the oil level with the engine stopped and with the machine on firm, level ground.

WARNING

Push the engine oil level dipstick completely down, and pull out before you check the oil level.

If the oil level is below the ADD mark (A), add oil to raise the oil level up to the FULL mark (B).

2

1

Hot coolant can spray out if radiator or deaeration tank cap is removed while system is hot. To remove cap, let system cool, turn to first notch, then WAIT until ALL pressure is released. Failure to comply could result in death or serious injury.

Coolant Solution Put only ethylene-glycol coolant solution in the cooling system. Use good quality ethylene-glycol that has a high boiling point with no additives to prevent l e a k a g e. D o n o t u s e n o n - a p p r o ve d a n ti - r u s t additives. Anti-rust additives and ethylene-glycol can m i x a n d w o r k a g a i n s t e a c h o t h e r, r e d u c i n g anti-corrosion, and causing damage to the cooling system and radiator.

Consult your CASE Dealer for suitable coolant solution.

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

Figure 11

CT07A079

1. ENGINE OIL DIPSTICK 2. ENGINE OIL FILL

A

1 2

CT07K026

B CT05L023

Figure 12

The oil level should be between the marks (A) and (B) on the dipstick.

NOTICE: The level should not be higher than the mark (B) maximum on the dipstick.

5-24

Figure 13

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.

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 10 HOUR MAINTENANCE

FAN AND ALTERNATOR DRIVE BELT

RADIATOR AND OIL COOLER

Visually check the fan and alternator drive belt before you start the engine each day or before the start of each 10 hour shift.

Check the radiator and oil cooler before you start the engine each day or before the start of each 10 hour shift.

CT07A098

CT07K026

Figure 14

CT07K026

Figure 15

Figure 16

Check for any signs of wear or damage to the pulleys or the belt. Check carefully to insure that the belt is correctly positioned in the pulley grooves. If the belt is stretched, cracked or frayed, it must be replaced.

Check for leakage on and around the radiator and oil cooler components. Check for any debris build-up around these components as well. Leaves, brush, etc. can create a fire hazard.

5-25

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 10 HOUR MAINTENANCE HYDRAULIC FLUID RESERVOIR LEVEL Service Specifications Reservoir capacity . . . . . . . . . . . 39 Gal. (147 Liters) Total system capacity . . . . . . . . 66 Gal. (250 Liters) Check the hydraulic fluid reservoir level before you start the engine each day or before the start of each 10 hour shift. Always check levels with the engine stopped and with the machine on firm, level ground.

NOTICE: After replacing the hydraulic fluid, it is necessary to bleed all air from the hydraulic components. See “Bleeding air from the hydraulic components”.

2. The oil should be in the middle of the indicator.

Add more oil if necessary.

WARNING Burn hazard!

Before performing any service on the hydraulic system, you must allow it to cool. Hydraulic fluid temperature should not exceed 40 °C (104 °F).

Failure to comply could result in death or serious injury.

W0241A

WARNING

Figure 18

CT06K088

WARNING Hydraulic oil leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: relieve all hydraulic pressure, before disconnecting fluid lines. If injured by leaking fluid, seek medical attention immediately.

Failure to comply could result in death or serious injury.

FILLING THE RESERVOIR

Avoid injury! Before carrying out any service work on hydraulic filters or the hydraulic system, remove the hydraulic reservoir breather cap, and press the button on the breather to release all pressure in the system. Failure to observe these instructions can cause injury. See “Releasing Pressure in the Hydraulic System”. Failure to comply could result in death or serious injury.

1. Release all pressure in the hydraulic reservoir.

See “Re leasing Pre ssure in th e Hyd rau lic System.”

Check Hydraulic Fluid Level In The Reservoir

CT06K102

Figure 19

2. Clean the cover plate and the area around the plate.

3. Remove the cover plate and add hydraulic fluid to the reservoir as required.

CS98N547

Figure 17

1. Keep all non-authorized personnel clear of the area. Position the machine on firm, level ground, and place the attachment on the ground. Stop the engine, and remove the starter switch key.

5-26

4. Replace the cover plate seal, and install the cover plate.

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 10 HOUR MAINTENANCE

FUEL FILTER BLEEDING

FUEL PREFILTER BLEEDING

Bleed the fuel filter before you start the engine each day or before the start of each 10 hour shift.

Check and drain the fuel prefilter before you start the engine each day or before the start of a 10 hour shift.

CT07A090 CT06M014

Figure 20

1. The fuel prefilter and fuel filter are located behind the right rear access door. Place a receptacle of a suitable capacity under the prefilter. Loosen the drain plug and drain the water and dirty fuel.

1. Place a container with a suitable capacity under the filters.

CT07A090

CT06M014

Figure 21

2. After draining, close the drain plug. Check for any signs of leakage.

Figure 22

Figure 23

2. Loosen the drain plug and drain the water and dirty fuel. After draining, retighten the bleed screw.

FUEL TANK SCREEN

CD01K039A

Figure 24

The fuel tank screen is located in the fuel tank filler neck. Clean the tank screen periodically. To clean, remove cap and filter. Clean the screen in diesel oil.

5-27

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 50 HOUR MAINTENANCE HYDRAULIC SYSTEM LINES

BOLT AND NUT TORQUE

Check hydraulic system lines when the machine is new at the initial 50 hour run-in period.

Check all bolts and nuts when the hour meter registers 50 hours. For torque information, see Section 6, Maintenance.

Service Specifications Reservoir capacity . . . . . . . . . . . 21.7Gal. (82 Liters) Total system capacity . . . . . . . 41.5 Gal. (157 Liters) NOTICE: After replacing the hydraulic fluid, it is necessary to bleed all air from the hydraulic components. See “Bleeding Air from the Hydraulic Components” at the beginning of this section.

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. Failure to comply could result in death or serious injury.

WARNING Burn hazard!

Before performing any service on the hydraulic system, you must allow it to cool. Hydraulic fluid temperature should not exceed 40 °C (104 °F).

Failure to comply could result in death or serious injury.

W0241A

5-28

AIR CONDITIONING Check the air conditioning for correct refrigerant level and filter replacement/cleaning if necessary. See Section 6, Maintenance.

BATTERY CHECK Check the battery fluid levels when the hour meter registers 50 hours. For additional information, See Section 7, Electrical

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE DRAINING WATER AND SEDIMENT FROM THE HYDRAULIC RESERVOIR

PILOT FILTER REPLACEMENT

Drain the hydraulic reservoir when the machine hour meter registers 250 hours or more often if conditions so require.

Figure 26

CT07A056

PILOT FILTER LOCATION

CT06M029

Figure 25

1. Keep all non-authorized personnel clear of the area. Release all pressure in the hydraulic reser voir. See “Releasing Pressure in th e Hydraulic System.”

2. Position a receptacle of suitable capacity under the drain plug.

Replace the pilot filter when the machine hour meter registers 250 hours during the initial run-in period.

The pilot filter will be replaced at 2000 hours thereafter, or sooner if conditions so require.

1. Keep all non-authorized personnel clear of the area. Release all pressure in the hydraulic system. See “Releasing Pressure in the Hydraulic System.”

3. Loosen the drain plug on the bottom of the reservoir, and drain the sediment and water accumulated at the bottom of the reservoir.

1 2

4. After draining, tighten the drain plug. Add hydraulic oil if necessary.

3 4

CS98M619

Figure 27

2. Use a wrench on the bottom of the filter body (4) to unscrew and remove it.

3. Remove the old filter (3) and the O-ring (2).

4. Clean the filter body (4) in solvent and wipe dry with a cloth.

5. Coat the new filter (3) and the new O-ring (2) with clean hydraulic fluid. Install the new filter on the head (1).

6. Install the filter body (4) and tighten by hand. Do not overtighten.

5-29

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE RETURN FILTER REPLACEMENT (RUN-IN) Replace the hydraulic return filter when the machine is new and the hour meter registers 250 hours.

Replace the hydraulic fluid return filter when the hour meter registers every 2000 hours thereafter or sooner if conditions so require.

1 2

3

1. Keep all non-authorized personnel clear of the area. Release all pressure in the hydraulic reser voir. See “Releasing Pressure in th e Hydraulic System.” Clean the top of the hydraulic reservoir and clean the return filter cover.

4

5

CT06K103

Figure 28

2. Remove the upper plate (1) on the hydraulic reservoir.

3. Clean the top of the hydraulic reservoir and clean the return filter cover.

CT07A048

Figure 29

4. Remove the cover (1) and O-ring (2).

5. Take out the spring (3), valve (4) and return filter (5).

6. Install a new filter. Clean the spring (3) and valve (4) and assemble them.

7. Check O-ring (2), and replace it if worn or damaged.

8. Install the cover (1).

9. Check the level of the hydraulic fluid and add m o r e f l u i d , i f n e c e s sa r y. S e e “ F il l in g t h e Reservoir”.

5-30

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE SWING REDUCTION GEAR (RUN-IN) Service Specifications Oil capacity . . . . . . . . . . . . . . . . . 2.3 Qts (2.2 Liters) Oil type . . . . . . . . . . . . . . . . . . . . . . . Case 135H EP

DRAINING AND REFILLING SWING REDUCTION GEAR OIL

3

Perform an oil change after the first 250 hours of operation during run-in. Check swing reduction gear oil level every 250 hours thereafter. An oil change is also required at each 1000 hour interval thereafter.

2

1

CT07K044

Figure 31

1. Keep all non-authorized personnel clear of the area. Park the machine on flat, level ground.

Stop the engine, and remove the starter switch key.

2. Remove the dipstick (1) and the filler plug (2).

CT07K036

Figure 30

1. Keep all non-authorized personnel clear of the machine. Park the machine on firm, level ground.

Stop the engine and remove the starter switch key.

2. To check the oil level, remove the dipstick (1).

The oil should come up to the hatched area. Add oil if necessary through the filler hole (2).

3. Install the dipstick.

3. Place a receptacle of a suitable capacity under the upper structure, and remove the drain plug (3).

4. Allow the oil to drain.

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

Check the condition of the drained oil. If it contains metal filings or foreign matter, see your CASE Dealer.

5. Install the drain plug (3).

6. Add oil through the filler holes (2) until the level is correct.

7. Install the dipstick (1) and the filler plugs (2).

8. Wait ten minutes and check the oil level again.

Add more oil, if necessary.

5-31

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE Draining And Refilling Travel Reduction Gears

TRAVEL REDUCTION GEARS (RUN-IN) Service Specifications Oil capacity . . . . . . . . . . . . . . . . . 2.2 Qts. (2.1 Liters) (per reduction gear) Oil type . . . . . . . . . . . . . . . . . . . . . . . Case 135 H EP 1. Change the travel reduction gear oil after the first 2 5 0 h o u r s o f o p e ra t i o n . C h e ck t h e t rave l reduction gear oil every 250 hours thereafter. An oil change is also required at each 1000 hour interval.

1. Park the machine on flat, level ground.

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

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

4. Place a receptacle of a suitable capacity under the travel reduction gear and remove plugs (1) and (2).

5. Allow the oil to drain.

3

NOTICE: Check the condition of the drained oil. If it contains metal filings or foreign matter, see your CASE Dealer.

6. Install plug (1), fill with oil through the plug hole (3) until oil comes up to the bottom edge of port (2).

2

7. Install plug (2) and repeat the procedure for the other travel reduction gear.

1

8. Travel slowly with the machine, and make certain there are no leaks.

CD01K025

Figure 32

2. Keep all non-authorized personnel clear of the area. Park the machine on flat, level ground.

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

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

5. Slowly loosen the plug (3) to release any residual pressure.

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

7. Install the plugs.

8. Repeat for the other travel reduction gear.

9. Travel slowly with the machine and make certain there are no leaks.

5-32

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE REPLACE THE FUEL PREFILTER Replace the fuel prefilter when the machine hour meter registers 250 hours or more often if conditions so require.

4

1 CT07A081

Figure 35

6. Clean the area around the sediment bowl (4), then remove the bowl from the filtering element by loosening it using the wrench provided with the machine.

Figure 33

CT07A088

1. Filters are located behind the right engine access door.

2. Place a receptacle of a suitable capacity under the prefilter.

3. Close the valve on the supply line (1).

7. Clean the sediment bowl (4). Check the condition of its seal and replace if the seal is damaged.

Apply a thin coat of oil on the new seal. Install the sediment bowl on a new filter element.

NOTICE: Only the filter element must be replaced, not the sediment bowl.

3

2

CT07A081 CT07A081

Figure 34

4. Loosen the bleed plug (2) and the plug (3). Allow the prefilter to drain.

5. Clean around the prefilter body. Remove the prefilter using the filter wrench provided with the machine.

Figure 36

8. Reinstall the assembly on the filter head by rotating the prefilter until the seal is in contact with the filter head. Tighten the body to a torque of 20 ft lbs to 23 ft lbs (27.5 to 31.3 Nm). Do not over tighten. Retighten the bleed plug (2).

9. Bleed the system.

NOTICE: In cold weather, the water can freeze on the top part of the bowl. Bleed after ice has melted.

5-33

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE AIR FILTER

LUBRICATE ATTACHMENT

Inspection

When the hour meter registers 250 hours, lubricate the attachment. See the Lubricating the Machine and Attachments at the beginning of this section.

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.

The hoses should be replaced before they are worn.

Dust Ejector

CD01K085

Figure 37

Periodically check the dust injector. Replace the primary air filter element every 1000 hours. The secondary element should be replaced at the same time. Do not clean the secondary element. It must be replaced. Replacing the air filter elements may be r e q u ir e d m o r e fr e q u e n tl y i n ext re m e ly d u s ty conditions.

If the air restriction message displays and/or the audible alarm device sounds, shut the engine off and find the cause of the problem.

It may be necessary to change and/or clean the filter elements if conditions are particularly dusty. Never clean the secondary element. It must always be replaced.

5-34

BOLT AND NUT TORQUE When the hour meter registers 250 hours, check the torque of nuts and bolts on the machine. See Section 6, Maintenance for torque information.

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 500 HOUR MAINTENANCE Perform the following when the machine hour meter registers 500 hours or warning gauges so indicate.

GREASING THE TURNTABLE TEETH

MACHINE GREASE POINTS Use the following grease: EP NLGI grade 2 MAT 3550 . . . . (for temperate and hot climates) -20°C to +60°C (-4° to 160° F) EP NLGI grade 0 MAT 3550 . . . . . (for cold climates) -40°C to +20°C (-40° to 68° F)

2

Figure 41

CD01L028

1. Every 500 hours, remove the inspection cover (1) and visually check the condition of the gear surface for any damage.

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.

1 2 CS98N551

Figure 38

4. If the presence of water is detected: A. Remove the protective panel from the lower, central area.

1

B. Remove the plug (2).

C. Discharge the water or cloudy grease.

D. Install plug (2).

E. Insert new grease through the port and install the cover (1).

WARNING CT06K090

Figure 39

Turntable bearing. . . . . . . . . . . . . . . . . . (2 locations)

2

CD010034

Avoid injury!

The machine and attachment should not be moved when lubricating. If a different position is required: clear the area, move attachment, stop the engine and lubricate the attachment. Repeat this procedure until the attachment is completely lubricated. Failure to comply could result in death or serious injury.

Figure 40

Turntable teeth . . . . . . . . . . . . . . . . . . . . . (1 location)

5-35

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 500 HOUR MAINTENANCE OIL CHANGE AND FILTER REPLACEMENT Service Specifications Oil Type. . . . . . . . . . . . . . . . . . CASE AKCELA No. 1 Oil Capacity with filter . . . . . . . . . . 18 Qts. (17 Liters) Change the engine oil more frequently than every 500 hours when the engine operating conditions are severe (frequent stopping and starting and high or low engine temperatures).

1. Park the machine on a flat, level area. Stop the engine, and remove the starter key. Oil will be easier to change if it is still warm (not hot). Before draining the oil, have a container that will hold the required oil quantity.

3

CT07K038

Figure 44

6. Clean the area around the filter (3) and remove it.

1

Figure 42

CT07A079

PH08325

2. Remove the oil filter cap (1).

Figure 45

7. To replace the filter, coat the seal of the new filter with a fine film of oil.

8. Install the new filter. Turn the filter until the seal comes into contact with the filter head, and turn an extra half turn by hand.

NOTICE: Do not use a filter wrench to tighten the filter. Excessive tightening can damage the filter and their seals.

2

9. Fill the engine with new engine oil. Install the oil filler cap.

CT05L033

Figure 43

3. Remove the protective cap (2) from the engine housing drain.

4. Screw the end of the extension drain hose provided with the machine onto the engine check valve. Place the other end in a container of suitable capacity and allow the oil to drain.

5. Remove the extension drain hose and install the protective cap on the housing check valve.

Return the extension drain hose to its storage compartment.

5-36

10. Run the engine for a few minutes, and make certain there are no leaks. Check the oil level again, and add more oil if necessary.

NOTICE: You must shorten the oil change interval if you use diesel fuel with a sulphur content of more than 0.5%.

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

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 500 HOUR MAINTENANCE REPLACING THE FUEL FILTER Replace the fuel filter when the hour meter registers 500 hours or more often if conditions require.

Figure 48

CT06M016

1 Figure 46

CT06K099

1. Filters are located behind the right engine access door.

2. Place a receptacle of a suitable capacity under the prefilter.

3. Close the valve on the supply line (1).

7. Install the new filter. Turn the filter until the seal comes into contact with the filter head. Tighten the body to a torque of 20 ft lbs to 23 ft lbs (27.5 to 31.3 Nm). Do not over tighten. Retighten the bleed plug (2).

8. Bleed the system.

NOTICE: Do not use a filter wrench to install the filter. Overtightening the filter can damage the seal and filter.

NOTICE: If the engine does not regain full power after replacing the filter, bleed the system.

WARNING Fire hazard!

Drain fuel, using a suitable container, in a well ventilated area away from any source of flame or sparks, including any appliances with a pilot light.

Failure to comply could result in death or serious injury.

2

CT06M016

Figure 47

4. Clean the area around the filter head.

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

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

NOTICE: Do not fill the new filter with fuel before installing.

5-37

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 500 HOUR MAINTENANCE BLEEDING THE SYSTEM It is necessary to bleed the fuel system when:

• The tank has been completely emptied.

• The fuel filter has been replaced.

• Parts of the fuel system have been removed for service or repair.

• The machine has been in storage.

1

2

Figure 49

CD01N034

To Bleed The System: 1. Loosen the knob of the priming pump (2).

Loosen the air bleed screw (1). Turn the starter switch key to the “ON” position. Turn the priming pump handle (2) to the left in order to release the spring.

2. Move the handle of the priming pump (2) up and down until no bubbles come out of the air bleed screw (1).

5-38

3. 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 spilled fuel. Start the engine, and check for fuel leakage.

WARNING Fire hazard!

Completely wipe off any fuel spills after replacing a filter element or bleeding the system. Failure to comply could result in death or serious injury.

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE Removing The Elements

AIR FILTER CLEANING/REPLACING Inspection 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.

The hoses should be replaced before they are worn.

CT07K041

Figure 51

1. Release the fasteners and remove the cover.

CT07K041

Figure 50

Replace the primary element every 1000 hours. The secondary element should be replaced at the same time. Do not clean the secondary element. It must be replaced. Replacing the air filter elements may be r e q u ir e d m o r e fr e q u e n tl y i n ext re m e ly d u s ty conditions.

If the air restriction message displays and/or the audible alarm sounds, shut the engine off and find the cause of the problem.

CT07K042

Figure 52

2. Remove the primary element.

Observe the air filter service intervals, as clean filters mean longer engine life.

CD00E117

Figure 53

3. Remove the secondary element. The secondary element should be replaced at the same time the primary element is replaced.

NOTICE: Do not clean the secondary element. It must be changed, not cleaned.

5-39

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE CLEANING THE FILTER ELEMENT If the primary element is dry, compressed air can be used to clean the element. Blow compressed air from the inside towards the outside of the element at low pressure. hold the air nozzle at least 3 cm (1 inch) from the filter element. Do not exceed 7 bar (100 psi) with the air pressure.

An inspection light can be used to check the filter for pin holes or tears. If any damage is present on the filter, replace the filter.

Do not clean the secondary filter. It must be replaced.

Always make certain the filters fit securely in the housing before replacing the air filter housing cover.

CT07K042

Figure 55

5. Install the new primary element.

WARNING Eye damage and dust inhalation hazard!

Compressed air can propel dirt, rust, etc. into the air. Wear eye and face protection when using compressed air.

Failure to comply could result in death or serious injury.

Installing The Air Filter Elements

CT07K0421

Figure 56

6. Install the cover and fasten in place.

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

CD00E117

Figure 54

4. Install the new secondary element and tighten the wing nut.

5-40

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE HYDRAULIC SYSTEM Service Specifications Reservoir capacity ....................................................................................................................... 21.7 Gal. (82 Liters) Total system capacity ............................................................................................................... 41.5 Gal. (157 Liters) Type of oil ............................................................................................................... Case Hy-Tran Ultra® (MAT 3505) NOTICE: If the machine is new or if a major part has been overhauled or replaced in the hydraulic system, replace the pilot filter and return filter after 250 hours of operation. After that, replace these filters at the stipulated interval.

Every 1000 operating hours, it is necessary to have the hydraulic fluid analyzed. See your CASE Dealer.

NOTICE: After replacing the hydraulic fluid, it is necessary to bleed all air from the hydraulic components. See “Bleeding air from the hydraulic components” at the beginning of this section.

NOTICE: If metal filings are discovered in the replaced filters, see your CASE Dealer.

WARNING

WARNING

Hydraulic oil under pressure can penetrate the skin and cause infection or other injury. To Prevent Personal Injury: Relieve all pressure, before disconnecting fluid lines. Before applying pressure, make sure all connections are tight and components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury.

Pressurized system!

Before carrying out any service work on hydraulic filters or the hydraulic system, remove the hydraulic reservoir breather cap and press the button on the breather to release all pressure in the system. See Releasing pressure in the Hydraulic System. Failure to comply could result in death or serious injury.

5-41

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE SWING REDUCTION GEAR Service Specifications Oil capacity . . . . . . . . . . . . . . . . . 2.3 Qts (2.2 Liters) Oil type . . . . . . . . . . . . . . . . . . . . . . . . Case 135H EP

DRAINING AND REFILLING SWING REDUCTION GEAR OIL

3

Perform an oil change after the first 250 hours of operation during run-in. Check swing reduction gear oil level every 250 hours thereafter. An oil change is also required at each 1000 hour interval thereafter.

2

1

CT07K044

Figure 58

1. Keep all non-authorized personnel clear of the area. Park the machine on flat, level ground.

Stop the engine, and remove the starter switch key.

2. Remove the dipstick (1) and the filler plug (2).

CT07K036

Figure 57

1. Keep all non-authorized personnel clear of the machine. Park the machine on firm, level ground.

Stop the engine and remove the starter switch key.

2. To check the oil level, remove the dipstick (1).

The oil should come up to the hatched area. Add oil if necessary through the filler hole (2).

3. Install the dipstick.

3. Place a receptacle of a suitable capacity under the upper structure, and remove the drain plug (3).

4. Allow the oil to drain.

The oil takes a relatively long time to drain. Check the condition of the drained oil. If it contains metal filings or foreign matter, see your CASE Dealer.

5. Install the drain plug (3).

6. Add oil through the filler holes (2) until the level is correct.

7. Install the dipstick (1) and the filler plugs (2).

8. Wait ten minutes and check the oil level again.

Add more oil, if necessary.

5-42

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE RESERVOIR BREATHER REPLACEMENT

1 2 3 5 4 CT06K102

Figure 59

1. Keep all non-authorized personnel clear of the area. Park the machine on flat, level ground.

Stop the engine, and remove the starter switch key.

2. Release all pressure in the hydraulic reservoir.

See “Releasing Pre ssu re in th e Hyd rau lic System.”

CS0E528

Figure 60

3. Press the button (1) to release pressure in the hydraulic reservoir.

4. Remove the nut (2) and the cover (3) from the breather.

5. Remove and discard the used filter (4).

6. Install a new element, making sure the seal (5) is facing upwards.

7. Install the assembly.

5-43

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE

Draining And Refilling

TRAVEL REDUCTION GEARS Service Specifications Oil capacity . . . . . . . . . . . . . . . . . 2.2 Qts. (2.1 Liters) (per reduction gear) Oil type . . . . . . . . . . . . . . See “Fluids and lubricants” Drain and refill the travel reduction gear oil when the hour meter registers 1000 hours or more often if conditions so require.

1. Keep all non-authorized personnel clear of the area. Park the machine on flat, level ground.

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

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

4. Slowly loosen the plug (2) to release any residual pressure.

5. Place a receptacle of a suitable capacity under the travel reduction gear and remove plugs (1) and (3).

2

6. Allow the oil to drain.

NOTICE: Check the condition of the drained oil. If it contains metal filings or foreign matter, see your CASE Dealer.

3

7. Install plug (1), fill with oil through the plug hole (2) until oil comes up to the bottom edge of plug hole (3).

1 CD00E074

Figure 61

8. Install plugs and repeat the procedure for the other travel reduction gear.

9. Travel slowly with the machine and make certain there are no leaks.

WARNING Travel reduction gear is under pressure. Keep your face and body clear of drains. Never attempt to service a hot machine. Allow the machine to cool before performing any service. Heat increases travel reduction gear oil pressure. Loosen plug slowly and wear face protection. Failure to comply could result in death or serious injury.

M1721

5-44

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 2000 HOUR MAINTENANCE Perform the following when the machine hour meter registers 2000 hours or warning gauges so indicate.

HYDRAULIC SYSTEM Service Specifications Reservoir capacity ........................................................................................................................ 39 Gal. (147 Liters) Total system capacity .................................................................................................................. 66 Gal. (250 Liters) Type of oil ............................................................................................................... Case Hy-Tran Ultra® (MAT 3505) NOTICE: If the machine is new or if a major part has been overhauled or replaced in the hydraulic system, replace the pilot filter and return filter after 50 hours of operation. After that, replace these filters at the stipulated interval.

NOTICE: After replacing the hydraulic fluid, it is necessary to bleed all air from the hydraulic components. See “Bleeding Air from the Hydraulic Components”.

NOTICE: If metal filings are discovered in the replaced filters, see your CASE Dealer.

CLEANING THE INLET FILTER 1. Park the machine on a firm, level surface. Keep all non-authorized personnel clear of the area.

Release all pressure in the hydraulic reservoir.

See “Releasing Pre ssu re in th e Hyd rau lic System.”

1 2 3

4

CT06K102

5

Figure 62

2. Clean the top of the hydraulic reservoir and the inlet filter cover.

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

4. Remove the inlet filter (3) and clean with solvent.

Dry completely and check for any damage. If there is any damage on the surface, replace with a new filter.

CT07A048

Figure 63

5. Install a new O-ring (2) and install the inlet filter (5), spring (3), and rod assembly (4).

6. Install the cover (1).

7. Check the level of the hydraulic fluid and add more if necessary. See “Filling the Reservoir”.

NOTICE: Install a new inlet filter when the hydraulic oil is replaced.

5-45

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 2000 HOUR MAINTENANCE RETURN FILTER REPLACEMENT

1

Replace the hydraulic return filter when the machine is new and the hour meter registers 250 hours.

Replace the hydraulic fluid return filter when the hour meter registers every 2000 hours thereafter or sooner if conditions so require.

2

3

1. Keep all non-authorized personnel clear of the area. Release all pressure in the hydraulic reser voir. See “Releasing Pressure in th e Hydraulic System.” Clean the top of the hydraulic reservoir and clean the return filter cover.

4

5

CT06K103

Figure 64

2. Remove the upper plate (1) on the hydraulic reservoir.

3. Clean the top of the hydraulic reservoir and clean the return filter cover.

CT07A048

Figure 65

4. Remove the cover (1) and O-ring (2).

5. Take out the spring (3), valve (4) and return filter (5).

6. Install a new filter. Clean the spring (3) and valve (4) and assemble them.

7. Check O-ring (2), and replace it if worn or damaged.

8. Install the cover (1).

9. Check the level of the hydraulic fluid and add m o r e f l u i d , i f n e c e s sa r y. S e e “ F il l in g t h e Reservoir”.

5-46

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 2000 HOUR MAINTENANCE

GREASE SWING REDUCTION GEAR

PILOT FILTER REPLACEMENT

Figure 68

CD01K025

Figure 66

CT07A056

PILOT FILTER LOCATION

Replace the pilot filter when the machine hour meter registers 250 hours during the initial run-in period.

The pilot filter should be replaced at 2000 hours thereafter, or sooner if conditions so require.

1. Keep all non-authorized personnel clear of the area. Release all pressure in the hydraulic system. See “Releasing Pressure in the Hydraulic System.”

Grease the swing reduction gear every 2000 hours or sooner if conditions so require.

Remove the lower panel, and remove the air bleed plug. Refill with grease through the grease point. A small amount of grease will run out from the air bleed plug. When greasing, if the air bleed plug is not removed, the inner seal will be damaged.

CLEANING THE FUEL TANK

1 2 3 4

CS98M619

Figure 69

CD01K077A

Figure 67

2. Use a wrench on the bottom of the filter body (4) to unscrew and remove it.

3. Remove the old filter (3) and the O-ring (2).

4. Clean the filter body (4) in solvent and wipe dry with a cloth.

5. Coat the new filter (3) and the new O-ring (2) with clean hydraulic fluid. Install the new filter on the head (1).

6. Install the filter body (4) and tighten by hand. Do not overtighten.

Clean the fuel tank when the hour meter registers 2000 hours.

1. Make certain the tank is empty. Remove the fuel tank cover located at the bottom of the tank.

Clean the tank, removing any sediment, etc.

2. Place the cover back into position, making certain it seats correctly. Fill with fuel, and check for any signs of seepage/leakage.

WARNING Fire hazard!

Drain fuel, using a suitable container, in a well ventilated area away from any source of flame or sparks, including any appliances with a pilot light.

Failure to comply could result in death or serious injury.

5-47

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 4000 HOUR MAINTENANCE DRAINING AND FILLING THE COOLING SYSTEM

Draining

Service Specifications System capacity . . . . . . . . . . . 15.4 Qts. (14.6 Liters) Type . . . . . . . . .50% water and 50% Ethylene Glycol Drain the engine coolant when the hour meter registers 4000 hours, flush the system, and refill with new coolant. If the low coolant or overheat message displays and/or the audible alarm device sounds, shut the engine off, and find the cause of the problem.

WARNING The engine coolant system operates under pressure which is controlled by the radiator pressure cap. It is dangerous to remove the pressure cap while the system is hot. When cool, use a thick cloth and turn the cap slowly to the first stop and allow the pressure to escape before fully removing the cap.

Coolant should be kept off the skin. Adhere to the precautions outlined on the antifreeze and inhibitor containers, where used. Failure to comply could result in death or serious injury.

CT07K026

Figure 70

1. Using the starter switch key, open the access hatch, then remove the radiator cap.

WARNING Do not remove the radiator cap when the engine is hot. The system is still under pressure, and you could be scalded. Failure to comply could result in death or serious injury.

Coolant solution

CT06M027

Figure 71

2. Have a receptacle of suitable capacity ready.

Open the radiator drain valve.

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 l e a k a g e. D o n o t u s e n o n - a p p r o ve d a n ti - r u s t additives. Anti-rust additives and ethylene-glycol can m i x a n d w o r k a g a i n s t e a c h o t h e r, r e d u c i n g 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.

Coolant Level The level of coolant solution should be checked when the engine is cold. Check coolant level on firm, level ground, before using the machine (while the engine is still cold). The level in the expansion reservoir should be between the “Full” (1) and “Low” (2) marks.

If not, see “Filling”.

5-48

CT06M028

Figure 72

3. Open the drain plug located on the engine block and drain into a receptacle of suitable capacity.

Allow the radiator to completely empty.

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 4000 HOUR MAINTENANCE Flushing

Filling

1. Close the drain valve once the radiator is completely empty. Close the plug on the engine block.

2. Fill the system with clean water. Install the radiator cap.

3. Keep all non-authorized personnel clear of the machine. Start the engine. Run the engine at a speed slightly higher than idle speed for ten minutes to bring the engine temperature up to about 80° C (176° F).

4. Drain the system once more.

5. Repeat Steps 1 to 4 until the water drained is clear.

CT07K026

Figure 73

1. Fill with coolant solution via the radiator until it overflows, install the radiator cap, then lock the access hatch.

CT07K0234

Figure 74

2. Fill the expansion reservoir to the “Full” mark and install the cap.

NOTICE: Use the correct coolant solution.

3. Run the engine at idle speed for about five minutes. Add coolant solution if the level in the expansion reservoir drops.

NOTICE: Do not fill the expansion reservoir above the “Full” mark.

5-49

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 5000 HOUR MAINTENANCE Service Specifications Total system capacity .................................................................................................................41.5 gal. (157 Liters) Reservoir capacity ........................................................................................................................21.7 gal. (82 Liters) Type of oil ............................................................................................................... Case Hy-Tran Ultra® (MAT 3505) REPLACING THE HYDRAULIC FLUID 1. Keep all unauthorized personnel clear of the area. Release all pressure in the hydraulic reser voir. See “Releasing Pressure in th e Hydraulic System.”

8. Start and run the engine with no load for approximately five minutes. Move each control slowly several times to remove any air in the system.

9. Swing the upper structure evenly left to right two turns or more.

10. Place the machine in position, and then stop the engine.

11. Check the oil level in the hydraulic reservoir and add oil as required. Make sure there are no air bubbles in the hydraulic reservoir.

WARNING

CT06K102

Figure 75

2. Remove the reservoir cover plate.

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

The hydraulic tank is a pressurized system. Vent tank slowly by loosening the breather slowly before performing work on hydraulic filters or the hydraulic system to prevent excess loss of fluid and serious injury. Failure to observe these instructions could cause injury.

M1285A

WARNING Attempting to operate a machine with malfunctioning or leaking components could cause death or serious injury. You must repair or replace any items found to be malfunctioning or leaking BEFORE operating the machine. Failure to follow these instructions could cause death or serious injury.

M1588

WARNING CT06M029

Figure 76

4. Remove the drain plug to remove the remaining fluid from the reservoir.

5. Replace the inlet filter. See “Cleaning and Replacement of the Inlet Filter”. Install the reservoir drain plug.

6. Put new hydraulic fluid into the reservoir. See “Filling the reservoir”. Install the reservoir cover plate and seal.

7. Before you start the engine, it is very important t h a t yo u b l e e d a i r f r o m a l l t h e hy d r a u l i c c o m p o n e n t s. S e e “ B l e e d i n g A i r fr o m t h e Hydraulic Components”.

5-50

Hydraulic oil leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: relieve all hydraulic pressure, before disconnecting fluid lines. Before applying pressure, make sure all connections are tight and components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, seek medical attention immediately. Failure to comply could result in death or serious injury.

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 5000 HOUR MAINTENANCE REPLACEMENT OF THE INLET FILTER

1

Replace the hydraulic fluid inlet filter when the hour meter registers 5000 hours or sooner if conditions so require.

2

1. Keep all non-authorized personnel clear of the area. Release all pressure in the hydraulic reser voir. See “Releasing Pressure in th e Hydraulic System.”

3

4

5

CT06K102

Figure 77

2. Clean the top of the hydraulic reservoir and clean the inlet filter cover.

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

4. Remove the inlet filter (5), replace with a new filter.

CT07A048

Figure 78

5. Install a new O-ring (2) and install the new inlet filter (5), spring (3) and rod assembly (4).

6. Install the cover (1).

7. Check the level of the hydraulic fluid and add more if necessary. See “Filling the Reservoir”.

5-51

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

NOTES

5-52

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Chapter 6 MAINTENANCE AND ADJUSTMENTS TABLE OF CONTENTS TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Track Shoe Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Radiator And Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Fan And Alternator Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Fuel Tank Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Inspecting And Cleaning The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 CAB PROTECTION (FOPS/ROPS- OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing A Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-10 6-11 6-11 6-12

CAB SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Air Conditioning (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Checking the quick coupler latching hook opening (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17 HARDWARE TORQUE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 TORQUE CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

6-1

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

6-2

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

TRACKS NOTICE: 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 working.

Cleaning

Checking Track Tension

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

1. Park the machine on firm, level ground. Keep all non-authorized personnel clear of the area.

2. Clean the tracks.

. .

CS01D529

Figure 1

1. Keep all non-authorized personnel clear of the machine. Move the machine to firm, level ground.

CS01D529

2. Position the upper structure 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.

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

3. Use the travel speed selector to select high speed.

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

Figure 2

3. Place the upper structure 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.

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

5. Repeat Steps 1 to 4 for the other track.

PEO7531

Figure 3

6. Measure the sag of the track at the center between the base of the undercarriage and the pad. The value should be 7.9 to 11.8 in (280 to 300 mm).

7. Adjust tension if necessary and then lower the raised track to the ground.

8. Repeat Steps 3 to 7 for the other track.

6-3

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Adjusting Tension

To Reduce Tension

Make any necessary track adjustments after the track tension has been checked.

.

To Increase Tension .

Figure 6

CT06M033

WARNING CT06M032

Figure 4

Pressurized fluid can penetrate the skin and cause severe injuries.

The grease in the track tensioning mechanism is under high pressure. Keep face and body away from grease nipple. Never loosen the grease nipple more than one complete turn.

Failure to comply could result in death or serious injury.

1. With the track in raised position, clean the grease fitting adaptor, and connect the grease pump hose to the grease fitting. .

W0959A

1. With the track in raised position, loosen the grease fitting adaptor about three turns to allow grease to flow out of the cylinder. .

PE07531

Figure 5

2. Connect the grease pump. Inject grease to obtain the right amount of track tension. The value should be 9.44 to 10.24 in (240 to 260 mm). Remove the grease pump, clean the grease fitting, and then lower the raised track to the ground.

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

PE07531

Figure 7

2. When the correct track tension is obtained, tighten the adaptor. The value should be 9.44 to 10.24 in (240 to 260 mm).

3. Clean the grease adaptor and fitting.

4. Lower the raised track, and repeat Steps 1 to 3 for the other track.

5. If the grease fitting adaptor is damaged, grease may leak out. Check the condition of the grease fitting ad ap tor regu la r ly, and re pla ce it, if necessary.

6-4

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TRACK SHOE BOLT TORQUE

TRACK ROLLERS AND IDLER WHEELS

Check track shoe bolt torque every 250 hours of machine operation.

1

3

4

2 CT07K047

CS00E504

Figure 8

Tighten in the order shown.

Figure 10

Check the track rollers and idler wheels every 250 hours.

The upper and lower rollers and idler wheels use a permanent floating seal type sealing mechanism.

This configuration will normally last until overhaul, but visually check for oil leakage. If any leakage is visible, consult your authorized dealer.

PE08316

Figure 9

Tighten the track shoe bolts to a torque of: 412 Nm + 39 Nm + 120° ± 5° (304 ft lbs ± 29 ft lbs).

6-5

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS RADIATOR AND OIL COOLER Clean the radiator and oil cooler area every 500 hours. Check daily or at ever y 10 shift for any leakage.

1 2 Figure 12

CT06K059A

3. Remove wing nuts (1) and protective grilles (2).

Figure 11

CT07K026

1. Keep all non-authorized personnel clear of the area. Stop the engine and remove the starter switch key.

CAUTION Falling engine hood can cause injury!

Engage the hood lock when the hood is open.

Failure to comply could result in minor or moderate injury.

2. Open the rear left hand side door and secure with the supporting strut. Open the engine hood, supporting properly.

6-6

4. Clean the radiator and compressed air or water.

oil coolers

using

5. Reinstall the protective grille and wing nuts.

6. Close and secure hood and all access doors prior to any machine travel.

WARNING Avoid injury!

Use safety type cleaning devices and wear full face protection if using pressurized water jets. Failure to comply could result in death or serious injury.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS FAN AND ALTERNATOR DRIVE BELT

Tension Adjustment

Check the fan and alternator drive belt tension when the hour meter registers 500 hours. Adjust or the replace the belt if necessary.

3

Visually check the fan and alternator drive belt daily.

Tension Check

2

1

Figure 15

CT06M018

To adjust tension, loosen the mounting bolts (1). Use the adjustment screws (2) to move the alternator outwards until belt tension is correct. Retighten the pulley attachment to a torque of 147 Nm (108 ft lbs).

Tighten the alternator mounting bolt.

CT06M018

Figure 13

Replacing Drive Belt

3

2 CS98M560

1

Figure 14

With the engine off, and the star ter switch key removed, press the center of the belt, exerting a pressure of about 10 kg (20 lbs). The belt deflection should be about 7 to 8 mm (.2 to .3 in).

Check if there are any signs of wear damage to the pulleys or the belt. Check carefully to insure that the belt is correctly positioned in the pulley grooves. If the belt is stretched, cracked or frayed, it must be replaced.

CT06M018

Figure 16

1. Remove the retaining screws (1) and (2). Use the adjustment screws (3) to push the alternator inwards.

2. Remove the worn belt.

3. Install a new belt. Adjust the belt using the screw (3).

4. Tighten the retaining screws (1) and (2).

5. Run the engine for about an hour, and then check the belt tension again.

If the engine runs with the belt slack, the belt can slip in its housing and cause the engine to overheat or the battery to receive insufficient charge.

6-7

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS FUEL TANK FILTER

INSPECTING AND CLEANING THE MACHINE

The fuel tank screen should be cleaned periodically.

Inspect and clean the machine periodically or whenever oil or grease has been spilled on the machine. Clean off with steam or a high pressure water jet. Use personal protection equipment when cleaning the machine.

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 c o n d i ti o n o f a l l p i p e s a n d h o s e s. R e p a i r a l l maintenance issues found.

Figure 17

CD01K024B

Remove the screen and clean it in diesel fuel.

NOTICE: To refill the fuel tank, see “Fluids and Lubricants” in the Lubrication/Filters/Fluids Section.

WARNING Fire hazard!

When handling diesel fuel, observe the following precautions: 1. Do not smoke.

2. Never fill the tank when the engine is running.

3. Wipe up spilled fuel immediately.

Failure to comply could result in death or serious injury.

WELDING ON THE MACHINE Whenever carrying out a welding operation on the un dercarr iag e or upp er str uctu re ca rr iag e 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 ground 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 upper structure (or vice-versa). Never connect the welding apparatus ground to a component of the hydraulic system.

NOTICE: Before you use an electric welder, disconnect the alternator wires, instrument cluster, and turn the master disconnect switch to OFF.

W0099A

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

Failure to comply could result in death or serious injury.

6-8

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Checking For Cylinder Leakage 3. Extend the cylinder rod.

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.

4. Carry out the leak test by applying a piece of paper to the rod.

1. Wipe the cylinder rod and bearing off.

2. Operate normally for five or ten minutes.

Rod appearance Dry Slightly oily Oily

Test

Conclusion

Slight traces of oil when a piece of paper is wiped over 20 cm of the rod.

Normal

Paper remains stuck to rod when run over rod.

Normal

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 When cleaning plastic parts such as 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.

FIRE EXTINGUISHER A f ir e ex t in g u i s h e r o n th e m a c h in e i s h ig h ly re co mme nded . Eve r y mo nth exam ine th e fire extinguisher and make certain it is in good working order. Ever y six months, have the extinguisher checked by a certified supplier. Have any necessary maintenance to the extinguisher perfor med to maintain optimum working order.

6-9

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CAB PROTECTION (FOPS/ROPS- OPTION) An optional FOPS (Falling Object Protection) or ROPS (Roll Over Protection) will protect the cab from falling objects or roll. Check the FOPS/ROPS at the 50 hour run-in period and every 250 hours thereafter.

WARNING Yo u r m a c h in e i s e q u i p p e d w i th a n o p e ra t o r Protective Structure, such as: Rollover Protective Structure (ROPS) or Falling Object Protective Structure (FOPS).

The Pr otective S tr ucture is a special s afety component of your machine.

DO NOT attach any device to the Protective Structure for pulling purposes. DO NOT drill holes into the Protective Structure.

The Protective Structure and interconnecting components are a certified system. Any damage, fire, corrosion or modification will weaken the structure and reduce your protection. If this occurs, the Protective Structure MUST be replaced so that it will provide the same protection as a new Protective Structure. Contact your dealer for Protective Structure inspection and replacement.

After an accident, fire, tip or roll over, the following MUST be performed by a qualified technician before returning the machine to field or job site operation: The protective structure MUST be replaced.

CD04D008A

Figure 18

C h e ck t h e F O P S / RO P S r e ta i n i n g h a r d w a r e .

Retighten and hardware as necessary. Check to make certain there are no cracks, rust, or holes that can compromise the protective features.

If the protective structure has suffered any damage due to an accident, it is necessary to replace the damaged components. Do not weld or alter the FOPS/ROPS.

6-10

The mounting or suspension for the Protective Structure, operator seat and suspension, seat belts and mounting components and wiring within the operator’s protective system MUST be carefully inspected for damage.

All damaged parts MUST be replaced.

DO NOT WELD, DRILL HOLES, ATTEMPT TO STRAIGHTEN OR REPAIR THE PROTECTIVE STRUCTURE. MODIFICATION IN ANY WAY CAN REDUCE THE STRUCTURAL INTEGRITY OF THE STRUCTURE WHICH COULD CAUSE DEATH OR SERIOUS INJURY IN THE EVENT OF FIRE, TIP, ROLLOVER, COLLISION OR ACCIDENT

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS REPLACING A BUCKET REMOVAL 1. Keep all non-authorized personnel clear of the area. Position the bucket flat on fir m, level ground. Operate the attachment controls so that the arm/bucket linkage pin is not held in place by the weight of the arm.

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

CD0E099

Figure 21

5. Start the engine, disengage the attachment from the bucket and retain the linkage seals for reuse.

CD00E096

Figure 19

3. Remove the retaining rings and pins.

CD00E097

Figure 20

4. Remove the bucket pins.

6-11

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS INSTALLATION 1. Make sure the bucket is in a stable position.

Figure 24

CD00E096

CD00E099

Figure 22

2. Install the linkage seals on the arm bushing shoulders. Change them if necessary.

3. Keep all non-authorized personnel clear of the area. Star t the eng ine. Exte nd th e bucke t cylinder rod to bring it into its housing. Stop the engine, and remove the starter switch key.

6. Install the connecting arm/bucket linkage pin, and then install the retaining pin and ring.

7. Push the seals back into their housing.

8. Adjust the arm/bucket shimming.

9. Grease the linkages.

WARNING Pinch hazard!

Always use suitable tools to align holes. DO NOT USE HAND OR FINGERS. Failure to comply could result in death or serious injury.

B020A

CD00E100

Figure 23

4. Install the arm/bucket linkage pin and then install the retaining pin and ring.

5. Start the engine, and bring the bucket connecting rod into its housing. Stop the engine, and remove the starter switch key.

6-12

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Replacing a tooth on the bucket

Shimming the Bucket

1

J 2 CD00E121

Figure 25

Side Play Adjustment 1. Place the bucket firm on level, firm ground.

2. Check the play (J) between the arm and the bucket ear.

3. If the play (J) exceeds 2 mm (.07 in), remove the four screws, the cap (1) and the shims (2).

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

5. Install the necessary number of shims.

6. Install the cap (1) and the four screws.

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

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 certain the lug is inside this orifice.

CD01D128

Figure 26

REMOVAL 1. Keep all non-authorized personnel clear of the area. Position the bucket a few inches above the ground. Stop the engine and remove the starter switch key.

2. Use a drift to remove the locking pin from its housing by striking it with a hammer until it is ejected.

3. Remove the worn tooth tip, turning it to the left.

INSTALLATION 1. Clean the mating surface on the adaptor.

2. Install a new tooth tip up to the stop, turning it to the right and holding it in this position.

3. Place the locking pin in position, and strike it until it is flush with the tooth tip.

NOTICE: Make sure that the latch has been installed with the correct orientation.

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

TEETH AND TOOTH TIP WEAR LIMITS The degree to which teeth or tooth tips are worn can be assessed visually.

It is possible to extend the life of teeth or tooth tips which are wearing unevenly in a non-symmetrical fashion by interchanging them regularly.

NOTICE: Do not wait for teeth or tooth tips to be completely worn through before changing them.

Never try to work with a missing tooth tip or a tooth tip which is worn through. The adaptor could be seriously damaged.

6-13

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

CAB SERVICE AIR CONDITIONING (IF EQUIPPED) The components of the operator’s cab, including the components of the air conditioning system, require service at different intervals. Service the following items as required to maintain maximum operating efficiency.

WARNING Liquid refrigerant can cause severe and painful frostbite to your skin. Do not attempt to service the air conditioning system on this machine unless you are completely familiarized with air conditioning systems and the safety precautions which must be followed. Failure to comply could result in death or serious injury.

SA048

Lubrication Of The Air Conditioning Compressor Seals Operate the air conditioning once every 250 hours to lu b r ic a t e t h e c o m p r e s s o r s e a l s. Tu r n t h e a ir conditioning control to MAXIMUM for at least 15 minutes. In temperatures below 32°F (0°C) put a cover over the air conditioning condenser. This will allow the refrigerant and lubricants in the system to be at operating temperature.

Keep the air conditioning condenser core clean. Use compressed air (wear face protection) or a rigid brush to clean the condenser. Also check and clean the grille screen.

NOTICE: Because the condenser fins bend easily, use care when cleaning the condenser.

6-14

Inspection In order to insure the air conditioning functions correctly, inspect the air conditioner using the procedure outlined below prior to starting work.

Cleanliness of the Condenser If the condenser is dirty, it will not dissipate heat properly. Clean the condenser in water.

IMPORTANT: Never use water under pressure to clean the condenser.

Check the Air Conditioning Lines Make a visual check of lines and make certain there is no accumulation of dust, grease, etc.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Checking The Air Conditioning Circuit Charge Level

CT02D235

Figure 27

CT06M035

1. Turn on the air conditioning system, increase engine speed slightly (1400 to 1600 rpm) and look for bubbles through the sight glass.

A

B

3. Check the air conditioning connectors to make certain they are not dusty or dirty.

AIR CONDITIONING DRIVE BELT

C

CT7K049 CS00E555

Figure 29

Figure 28

2. This check should be made approximately one minute after turning on the air conditioning.

A. Few bubbles observed. Transparent at first, then whitish. “Normal”.

Figure 30

With engine off, exert pressure of approximately 10 kg (22 lb force) on the center of the air conditioning drive belt. The amount of deflection should be between 6 to 8 mm (.2 to .3 in). Adjust the tension of the belt if necessary.

B. Many bubbles. Check all connections and see your CASE Dealer.

C. No bubbles visible. Check all connections and see your CASE Dealer.

6-15

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS 3. Remove the filter, and clean it with compressed air. Replace the filter if it is damaged.

CLEANING THE AIR INTAKE FILTER

1

4. Install the filter in its housing with the seal (5) on the inside.

2

5. Close the panel (4) and install the screws (3).

6. Install the sealing cover (1) and the screws.

CLEANING THE AIR RECYCLING FILTER

Figure 31

CT07K050

1. Clean the air intake filter every 50 hours.

Remove the screws (2) and sealing cover (1) in the battery compartment.

Figure 34

CT06K036

3

1. The air recycling filter should be cleaned every 50 hours. Th e filter is located behind the operator’s seat. Remove the access panel and take out the filter (1).

4

1 Figure 32

CT06K111

2. Remove the screws (3) and open the panel (4).

5

Figure 35

CT06K113

WARNING

Figure 33

CT06K112

WARNING Avoid injury!

Use a safety type air gun and always protect your face before using compressed air.

Failure to comply could result in death or serious injury.

6-16

Avoid injury!

Use a safety type air gun and always protect your face before using compressed air.

Failure to comply could result in death or serious injury.

2. Clean the filter (1) with compressed air. Replace the filter if it is damaged.

3. Install the filter and the access panel.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CHECKING THE QUICK COUPLER LATCHING HOOK OPENING (optional) MAINTENANCE SPECIFICATION Check .........................................................................................Weekly and each time the quick coupler is installed

1

2

3

S CT06K112

Figure 36

1. Place the switch in unlocking position. The audible alarm device will sound. See "Quick coupler locking and unlocking switch" in section 4.

Figure 38

CS00J511

3. Check the opening measurement (S) of the latching hook.

Under no circumstances may the measurement (S) exceed Locking bar resting on surface (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102.7 mm (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.5 mm (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.5 mm Otherwise, consult your CASE Dealer.

Make sure the locking bar is not damaged. Check that it functions correctly and is not fouled by foreign matter.

CT02C242

Figure 37

2. Operate the bucket control to retract the cylinder rod completely and maintain the hydraulic pressure so the latching hook retracts and comes up against the locking bar.

WARNING Falling object hazard!

If the measurement (S) exceeds the maximum authorized value, do not use the quick coupler.

Contact your dealer.

Failure to comply could result in death or serious injury.

W0270A

INCORRECT OPERATION OF THE QUICK COUPLER Make sure that the attachment is resting on the ground. Shut down the engine and remove the starter switch key before carrying out.

6-17

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

HARDWARE TORQUE INSPECTION At the end of each working day, check all mounting nuts and screws for tightness and tighten, if necessary. Make sure no hardware items are missing. Replace them, if necessary.

TORQUE SPECIFICATIONS PER COMPONENT

Component

Bolt Size

Torque (Ft.Lbs)

Torque (Nm)

Travel reduction gear (*)

M16

197-230

267-312

Drive sprocket (*)

M16

197-230

267-312

Idler wheel (*)

M16

197-230

267-312

Upper roller (*)

M20

384-448

521-608

Lower roller (*)

M18

274-319

371-432

Chain guide (*)

M18

295-341

400-462

Track shoe

M20

221

300 + 120°

Counterweight

M33

1373-1518

1862-2058

Turntable undercarriage

M20/M24

345-402 578-674

468-545 784-914

Turntable upper structure

M20/M24

345-402 578-674

468-545 784-914

Swing reduction gear (*)

M20/M24

398-465 578-674

539-630 784-914

Engine (*)

M16

152-202

206-247

Engine mounts (*)

M10

47-54

64-73

Radiator

M16

108-131

147-177

Hydraulic pump (*)

M10 M20

47-54 271-366

64-73 367-496

Hydraulic reservoir (*)

M16

171-204

232-276

Fuel tank (*)

M16

171-204

232-276

Control valve (*)

M16

243-266

330-360

Hydraulic swivel (*)

M12

79-139

107-188

Cab

M16

116

157

Battery

M10

15-21

20-29

NOTICE: Use Loctite 262, or the equivalent, on bolts marked (*).

6-18

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

TORQUE CHARTS Use these charts when special torques are not given. These torques apply to fasteners with both UNC and UNF threads as received from suppliers dry, or when lubricated with engine oil. Not applicable if special graphite, Molydisulfide greases, or other extreme pressure lubricants are used.

Grade 8 Bolts, Nuts, and Studs

Grade 5 Bolts, Nuts, and Studs

PoundInches

Newton metres

1/4 inch

108 to 132

12 to 15

5/16 inch

204 to 252

23 to 28

3/8 inch

420 to 504

48 to 57

7/16 inch

54 to 64

73 to 87

1/2 inch

80 to 96

109 to 130

9/16 inch

110 to 132

149 to 179

5/8 inch

150 to 180

203 to 244

3/4 inch

270 to 324

366 to 439

7/8 inch

400 to 480

542 to 651

1.0 inch

580 to 696

787 to 944

1-1/8 inch

800 to 880

1085 to 1193

1-1/4 inch

1120 to 1240

1519 to 1681

1-3/8 inch

1460 to 1680

1980 to 2278

1-1/2 inch

1940 to 2200

2631 to 2983

Size

PoundInches

Newton metres

1/4 inch

144 to 180

16 to 20

5/16 inch

288 to 348

33 to 39

3/8 inch

540 to 648

61 to 73

7/16 inch

70 to 84

95 to 114

1/2 inch

110 to 132

149 to 179

9/16 inch

160 to 192

217 to 260

5/8 inch

220 to 264

298 to 358

3/4 inch

380 to 456

515 to 618

7/8 inch

600 to 720

814 to 976

1.0 inch

900 to 1080

1220 to 1465

1-1/8 inch

1280 to 1440

1736 to 1953

1-1/4 inch

1820 to 2000

2468 to 2712

1-3/8 inch

2380 to 2720

3227 to 3688

1-1/2 inch

3160 to 3560

4285 to 4827

Size

NOTE: Use thick nuts with Grade 8 bolts.

6-19

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

6-20

CHAPTER 7 - ELECTRICAL

Chapter 7 ELECTRICAL TABLE OF CONTENTS ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning the Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking The Battery Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing a Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Booster Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3 7-3 7-4 7-4 7-4 7-4 7-5 7-5 7-6

FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Replacing A Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7-1

CHAPTER 7 - ELECTRICAL

7-2

CHAPTER 7 - ELECTRICAL

ELECTRICAL SYSTEM BATTERY SAFETY

WARNING

WARNING

Sparks or flame can cause hydrogen gas in a battery to explode. To prevent an explosion, do the following: 1. When you disconnect the battery cables, always disconnect the negative (-) battery cable first. 2. When you connect the battery cables, always connect the negative (-) battery cable first. 3.

Do not short circuit the battery posts with metal items. 4. Do not weld, grind or smoke near a battery.

Failure to comply could cause death or serious injury.

Before you service a battery, always wear face protection, protective gloves and protective clothing.

Battery acid or battery explosion can cause serious injuries. Failure to comply could result in death or serious injury.

WARNING Batteries give off explosive gases. Keep all open flames, sparks and cigarettes away. Insure adequate ventilation when charging batteries or when using in a confined place. Always protect your eyes when working near batteries. Failure to comply could cause death or serious injury.

WARNING When the battery electrolyte is frozen, the battery can explode if, (1) you try to charge the battery, or (2) you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured. Failure to comply could result in death or serious injury.

WARNING WARNING Avoid injury!

Do not reverse battery terminals. Connect positive cable ends to positive (+) terminals and negative cable ends to negative terminals (-). Failure to comply could result in death or serious injury.

Avoid injury!

Before any operation on the components of the electrical circuit, turn the key switch to the off position. When disconnecting the battery cables, always disconnect the negative (-) cable first. When reconnecting the battery cables, always connect the negative (-) cable last. Failure to comply could result in death or serious injury.

WARNING WARNING: Battery acid causes severe burns.

Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote - EXTERNAL: flush with water.

INTERNAL: drink large quantities of water or milk.

Follow with milk of magnesia, beaten egg or vegetable oil. Call physician immediately.

EYES: flush with water for 15 minutes and get prompt medical attention. Failure to comply could result in death or serious injury.

7-3

CHAPTER 7 - ELECTRICAL BATTERY SERVICE Before you service components of the electrical system, always disconnect the NEGATIVE (-) battery cable.

Dir t, moisture, and corrosion on the battery will discharge the battery. Clean the battery with Case Battery Saver and Cleaner. Follow the instructions on the container.

Disconnect the alternator wires if you must run the engine with the battery wires disconnected.

Before you use an electric welder, disconnect the alternator wires, instrument cluster, and turn the master disconnect switch to OFF. Do not use a steam cleaner or cleaning solvent to clean the alternator.

BATTERY FLUID LEVEL Check the fluid level of the batteries every 500 hours of operation. If the fluid level is low, add distilled water to each cell until the fluid level is at the split ring at the bottom of each cell opening.

In extreme heat conditions check battery fluid every 250 hours.

ACCESSING BATTERIES

CT06K074

IMPORTANT: If the temperature is 0° C (32° F) or below and you have added water to the batteries, you must: Connect a battery charger to the batteries or operate the machine for approximately two hours.

This procedure is necessary to mix the water with the electrolyte.

BATTERY VENTS Keep the battery vents clean, make sure the vents are not restricted.

CLEANING THE BATTERIES Check the batter ies and batter y compar tment regularly for dirt, corrosion and damage. Dirt mixed with electrolyte or moisture on the top of the batteries can cause a discharged condition in the batteries.

Use one of the following methods to clean the batteries.

• Use Case Battery Saver, Part Number M20376.

Follow the instructions on the container. This cleaner does not need water.

Use baking soda or ammonia and flush the outside of the batteries with water. If you do not have Case Battery Saver, use other special cleaners to prevent corrosion on the battery terminals.

MAINTENANCE FREE BATTERY

Figure 1

To access the batteries, open the left hand side door, and remove the skid plate.

CT07A103

Figure 2

The charge indicator on the batter y shows the battery state of charge.

Green: Charge is correct.

Black: Insufficient charge. Recharge battery until indicator turns green.

Transparent (colorless: Replace battery as soon as possible.

7-4

CHAPTER 7 - ELECTRICAL REPLACING A BATTERY

CHECKING THE BATTERY ELECTROLYTE LEVEL

CD0E094 CD01D132

Figure 3

To gain access to the batteries, open the left-hand side door and remove the skid plate.

Remove the cell caps and check the level in each cell of both batteries. The level should be between 10 and 15 mm (.3 to .5 in) above the plates. Add distilled water if necessary, then install the cell caps.

NOTICE: When adding distilled water at temperatures below 0°C (32° F), the batteries must be charged or the engine run for two hours approximately in order to insure that the distilled water and the electrolyte are properly mixed.

NOTICE: Make sure the battery terminals are clean and coated with grease and that the cables are properly tightened.

Figure 4

Remove the terminal protection caps, disconnect cables at negative terminals and then disconnect cables at positive terminals. Remove the anti-sulfate pellets from the posts.

Remove the two screws, the washers and metal sheet. Remove the old battery.

Install the new battery and put the metal sheet, washers and screws back in place.

Clean the cables and battery terminals, and coat them with grease.

Install new anti-sulfate pellets, reconnect positive cable ends to positive ter minals first and then negative cable ends to negative terminals. Install the terminal protection caps.

7-5

CHAPTER 7 - ELECTRICAL CONNECTING BOOSTER BATTERIES

WARNING An error connecting auxiliary cables or short circuiting battery terminals can cause an accident. Make certain booster batteries and cables are connected correctly. Failure to comply could result in death or serious injury.

WARNING Avoid injury!

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. Failure to comply could result in death or serious injury.

Make sure that the voltage of the booster batteries is the same as that of the machine system.

1. Turn off the ignition and all accessories on the machine(s). Remove the battery terminal covers.

2. Connect one end of the positive (+) cable to the positive (+) terminal on the booster battery.

Connect the other end of the positive (+) cable to the positive (+) ter minal of the discharged battery.

3. Connect the negative (-) cable to the negative (-) terminal on the booster battery.

4. Connect the other end of the negative cable to the engine block or frame of the machine with the discharged battery. Do not connect it to sheet metal or any rotating part, as damage can result.

5. Start the engine.

6. Remove the booster battery negative (-) cable from the machine, then from the booster battery.

Remove the positive (+) cable from the machine and then from the booster battery.

7. Install the terminal covers.

7-6

CHAPTER 7 - ELECTRICAL

FUSES AND RELAYS NOTICE: Before replacing a fuse, turn the starter switch key to “OFF”.

NOTICE: Never replace a fuse with a fuse of a different amperage.

CT06K036

Figure 5

To gain access to the fuses, open the panel at the rear of the operator’s compartment, and remove the cover.

A23955

Figure 7

A notice on the c ove r give s the function and amperage of each fuse.

NOTICE: To remove or install a fuse, use the notch in the upper right-hand corner of the cover.

NOTICE: Two spare fuses (10 amp and 20 amp) can be found on the inside of the fuse box cover.

CT06K037

Figure 6

To access the fuses, remove the cover of the box.

7-7

CHAPTER 7 - ELECTRICAL FUSES (1) Memory, cab light, car radio . . . . . . . . . . . . . 10 A (2) Engine pre-heating . . . . . . . . . . . . . . . . . . . . 30 A (3) Optional. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 A (4) Air conditioning, heater . . . . . . . . . . . . . . . . . . 5 A (5) Air conditioning condenser fan . . . . . . . . . . . 15 A (6) Air conditioning compressor . . . . . . . . . . . . . . 5 A (7) Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 A (8) Windshield wiper/washer . . . . . . . . . . . . . . . 15 A (9) Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 A (10) Cab light . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 A (11) Fuel filler pump (if equipped). . . . . . . . . . . . 20 A (12) Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 A (13) Cigarette lighter, operator’s seat . . . . . . . . . 15 A (14) DC rectifier . . . . . . . . . . . . . . . . . . . . . . . . . 10 A (15) Rotating beacon (not supplied) . . . . . . . . . . 10 A (16) Not used . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 A (17) Fuel supply pump . . . . . . . . . . . . . . . . . . . . 10 A (18) Not used . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 A (19) Hydraulic control cancellation . . . . . . . . . . . 10 A (20) Work lights . . . . . . . . . . . . . . . . . . . . . . . . . 15 A

KHP12180

1

10A

20A

11

2

30A

10A

12

10A

15A

4

5A

10A

14

5

15A

10A

15

6

5A

15A

16

10A

10A

15A

15A

10A

10A

15A

15A

3

7 8 9 10

CT06K073

7-8

13

17 18 19 20

Figure 8

CHAPTER 7 - ELECTRICAL REPLACING A BULB Cab Light

CD00E126

Figure 12

Figure 9

3. Pull the clip outwards, remove the bulb, and install a bulb of the same wattage (70 W).

2. Remove the bulb, and install a bulb of the same wattage (10 W).

NOTICE: Never put your fingers on a tungsten iodide bulb.

CD00E123

1. Remove the lens by hand.

3. Install the lens.

4. Install the clip and reconnect the plug.

5. Put the working light back into position, and install the mounting screws.

Work Light

CD00E124

Figure 10

1. Remove the four mounting screws.

CD00E125

Figure 11

2. Tilt the work light and disconnect the plug.

7-9

CHAPTER 7 - ELECTRICAL Upper Structure Work Light

CD00E129 CT06K057

Figure 13

1. Open the front storage box.

CT06K069

Figure 14

2. Remove the switch bracket to access the head lamp.

Figure 16

4. Remove four screws and tilt the working light (upper structure work light).

CD00E130

Figure 17

5. Pull the clip outwards, remove the bulb and install a bulb of the same wattage (70 W).

NOTICE: Never put your fingers on a tungsten iodide bulb.

6. Install the clip and the working light assembly.

7. Install the work light and plug (upper structure working light).

CD00E128

3. Disconnect the plug.

7-10

Figure 15

CHAPTER 8 - SPECIFICATIONS

Chapter 8 SPECIFICATIONS TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Working conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Operator's compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 CX130B monobloc boom 2.10 m (6.9 ft) and 2.50 m (8.2 ft) arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 (CX130B LC Type) (monobloc boom, 2.10 m (6.9 ft) and 2.50 m (8.2 ft) arm) . . . . . . . . . . . . . . . . . . . . . . . . 8-8 CX130B (monobloc boom 3.00 m (9.8 ft) Arm in transport position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 CX130B LC Type (monobloc boom 3.00 M (9.8 ft) Arm in Transport Position . . . . . . . . . . . . . . . . . . . . . . . . 8-10

8-1

CHAPTER 8 - SPECIFICATIONS

8-2

CHAPTER 8 - SPECIFICATIONS

SPECIFICATIONS NOTICE: All specifications are given according to SAE Standards or Recommended Practices where the specification applies.

ENGINE Latest "common rail" engine, in conformity with requirements applicable to low fumes emission.

Make and type ..................................................................................................................................ISUZU AJ-4JJ1X Common rail, intermediate cooler, fuel cooler ....................................................................................................... Yes Injection ................................................................................................................................. Electronically controlled Turbocharger ......................................................................................................................................................... Yes Number of cylinders...................................................................................................................................................4 Bore/stroke ................................................................................................... 95.4 mm x 104.9 mm (3.76 in x 4.13 in) Displacement............................................................................................................................. 2999 cm3 (413 cu in) Cooling .............................................................................................................................................................. Water Battery starting ................................................................................................................. 2 12/24 V batteries, 72 A/h WORKING CONDITIONS Speed ...........................................................................................................................................................2000 rpm EEC 80/1269 power .......................................................................................................................... 70.9 kW (96 hp) Engine oil capacity.............................................................................................................................. 17 l (18 quarts) Fuel tank capacity................................................................................................................................260 l (68.7 gal) Fuel filler pump .......................................................................................................................................... if equipped Engine/pump assembly mounted on flexible mountings.

Filtration in dusty conditions.

Electronically controlled governor.

HYDRAULIC SYSTEM Variable flow piston-type double pump.

Main pump max flow (at 2000 rpm).........................................................................2 x 129 l/min (2 x 136 qts/min) Fixed flow pump (pilot circuit).

Max. flow ............................................................................................................................. 22 l/min (23.2 qts/min) Fixed flow pump (dozer blade) (if equipped).

Max. flow ................................................................................................................................ 54 l/min (57 qts/min) Working pressure.

Attachment/power boost........................................................................................... 343/363 bar (4975/5265 PSI) Oil cooler with air cooling from engine.

High pressure multispiral hoses minimum safety factor .....................................2 to 4 times the working pressure Self-lubricating hydraulic swivel.

Hydraulic reservoir capacity .................................................................................................................82 l (87 qts) Total hydraulic system capacity .......................................................................................................157 l (41.5 gal) CONTROL VALVE Four control valve sections for right-hand travel, boom/bucket and dipper acceleration.

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

One control valve section for the dozer blade (if equipped).

Boom/dipper load holding valves.

8-3

CHAPTER 8 - SPECIFICATIONS SWING Fixed flow, piston-type pump.

Automatic disk brake.

Upper structure swing speed .........................................................................................................................14.3 rpm TRAVEL Two speed hydraulic motors with axial pistons.

Planetary reduction gears.

Low speed ..............................................................................................................................0 to 3.4 km/h (2.1 mph) High speed .............................................................................................................................0 to 5.6 km/h (3.5 mph) Gradeability ..........................................................................................................................................................70% ATTACHMENT Crowd force ........................................................................................................................ 9500 daN (10.7 ton force) Break-out force (with 2.10 m dipper) .................................................................................... 7400 daN (8.3 ton force) Break-out force (with 2.50 m dipper) .................................................................................... 6600 daN (7.4 ton force) Break-out force (with 3.00 m dipper) .................................................................................... 6000 daN (7.7 ton force) UNDERCARRIAGE One-piece frame with welded components.

Lubricated track rollers and idler wheels.

Grease cylinder track tension system.

Steel tracks .................................................................. 500 mm, 600 mm and 700 mm (19.7 in, 23.6 in, and 27.6 in) (CX130B) Ground pressure with 600 mm track pads and: (Monobloc boom) .............................................................................................................................0.34 bar (4.9 psi) (Monobloc boom + dozer blade) .......................................................................................................0.41 bar (5.9 psi) (CX130B LC Type) Ground pressure with 600 mm track pads and: (Monobloc boom) .............................................................................................................................0.32 bar (4.6 psi) SAFETY DEVICES Control for lowering attachments in case of engine failure.

Controls are disabled by lifting the function cancellation lever or the left-hand control arm.

Engine emergency shut-down, anti-theft protection.

Safety glass, double horn.

Safety valves with overload indicator.............................................................................................................. optional Inertia reel type safety belt.

Fire extinguisher ............................................................................................................................................. optional

8-4

CHAPTER 8 - SPECIFICATIONS OPERATOR'S COMPARTMENT Deluxe operator's seat with armrests, inertia type safety belt, multi-position adjustment and headrest Hydraulically assisted controls.

Attachment and swing .........................................................................................................................2 control levers Travel ................................................................................................................................................2 levers/2 pedals Dozer blade (if equipped) ................................................................................................................................. 1 lever Speed programmer, also provides automatic speed change.

Single-speed wiper plus intermittent mode, washers, heating, defrost, ventilation/air conditioning, cab lights, cigarette lighter, 12 V socket, sun shield.

Working lights: One on upper structure ........................................................................................................................24 V (70 W) One on attachment.............................................................................................................................. 24 V (70 W) Two on cab .......................................................................................................................................... 24 V (70 W) CAB Removable, sound proof, mounted on flexible mountings.

Foldaway windscreen.

Rear window emergency exit.

Sun shield.

Sliding windows on door.

Prefitted for radio installation.

Roof curtain.

Roof hatch.

Wind shield protection grid (optional).

Cab protection (optional).

8-5

CHAPTER 8 - SPECIFICATIONS

WEIGHTS (CX130B) With monobloc boom, 2.50 m (8.2 ft) arm,.56 M3 (.73 yd3) backhoe bucket, 600 mm (23.6 in) pads, operator and full fuel tank ............................................................................................................................ 12 700 kg With dozer blade add........................................................................................................................................ 800 kg (CX130B LC Type) With monobloc boom,2.50 m (8.2 ft) arm,.56 M3 (.73 yd3) backhoe bucket, 600 mm (23.6 in) pads, operator and full fuel tank ............................................................................................................................ 13 000 kg

BOOMS Monobloc boom length .....................................................................................................................................4.63 m

ARMS Length...............................................................................................................................................................2.10 m 2.50 m 3.00 m

BACKHOE BUCKETS GENERAL PURPOSE SAE capacity (l)

190

260

330

450

560

640

720

800

Width - mm Width - in

350 14

450 18

600 24

750 30

900 35

1000 39

1100 43

1200 47

Weight - kg Weight - lb

270 595

300 661

330 728

370 816

410 904

440 970

470 1037

490 1080

HEAVY DUTY

DITCH CLEANING WITH TEETH OR BLADE

TRAPEZOID

SAE capacity (l)

640

720

300

620

760

340

Width - mm Width - in

1000 39

1100 43

2200 87

1500 59

1800 71

350-2100 14-83

Weight - kg Weight - lb

450 992

485 1009

430 947

469 1033

492 1085

363 800

DOZER BLADE (if equipped) Width .................................................................................................................................................... 2.59 M (8.5 ft) Height ................................................................................................................................................. 0.57 m (1.88 ft) Maximum lift height............................................................................................................................. 0.38 m (1.25 ft) Maximum depth .................................................................................................................................. 0.37 m (1.21 ft)

8-6

CHAPTER 8 - SPECIFICATIONS

MACHINE OVERALL DIMENSIONS CX130B MONOBLOC BOOM 2.10 M (6.9 FT) AND 2.50 M (8.2 FT) ARM N D

E

C

B

A

F

M K

G H I

J L CS00K509C

O 1

(A) 2.10 m (6.9 ft) arm .......................................................................................................................... 2.71 m (8.9 ft) (A) 2.50 m (8.2 ft) arm .......................................................................................................................... 2.81 m (9.2 ft) (B)......................................................................................................................................................... 2.79 m (9.2 ft) (C)......................................................................................................................................................... 2.82 m (9.3 ft) (D)......................................................................................................................................................... 2.54 m (8.3 ft) (E)......................................................................................................................................................... 2.13 m (7.0 ft) (F) ......................................................................................................................................................... 0.89 m (2.9 ft) (G) ........................................................................................................................................................ 2.79 m (9.2 ft) (H)....................................................................................................................................................... 3.50 m (11.5 ft) (I) (with dozer blade)........................................................................................................................... 4.02 m (13.2 ft) (J) ......................................................................................................................................................... 1.99 m (3.5 ft) (K) (standard track pads) .................................................................................................................... 0.60 m (1.96 ft) (L) with 500 mm (19.6 in) track pads .................................................................................................... 2.49 m (8.2 ft) (L) with 600 mm (23.6 in) track pads .................................................................................................... 2.59 m (8.5 ft) (L) (with 700 mm (27.5 in) track pads ................................................................................................... 2.69 m (8.8 ft) (M) ........................................................................................................................................................ 0.44 m (1.4 ft) (N) 2.10 m (6.9 ft) arm ........................................................................................................................... 7.61 m (24.9) (N) 2.50 m (8.2 ft) arm)....................................................................................................................... 7.62 m (25.0 ft) (O) 2.10 m (6.9 ft) arm and dozer blade ............................................................................................. 7.75 m (25.4 ft) (O) 2.50 m (8.2 ft) arm and dozer blade ............................................................................................. 7.76 m (25.5 ft)

8-7

CHAPTER 8 - SPECIFICATIONS (CX130B LC TYPE) (MONOBLOC BOOM, 2.10 M (6.9 FT) AND 2.50 M (8.2 FT) ARM) N D

E

C

B

A

F

M K J L

G H

CS00K509D

2 (A) 2.10 m (6.9 ft) arm .......................................................................................................................... 2.71 m (8.9 ft) (A) 2.50 m (8.2 ft) arm .......................................................................................................................... 2.81 m (9.2 ft) (B)......................................................................................................................................................... 2.79 m (9.2 ft) (C)......................................................................................................................................................... 2.82 m (9.3 ft) (D)......................................................................................................................................................... 2.54 m (8.3 ft) (E)......................................................................................................................................................... 2.13 m (7.0 ft) (F) ......................................................................................................................................................... 0.89 m (2.9 ft) (G) ...................................................................................................................................................... 3.04 m (10.0 ft) (H)....................................................................................................................................................... 3.76 m (12.3 ft) (J) ......................................................................................................................................................... 1.99 m (6.5 ft) (K) (standard track pads) ....................................................................................................................0.60 m (23.6 in) (L) (with 500 mm (19.6 in) track pads).................................................................................................. 2.49 m (8.2 ft) (L) (with 600 mm (23.6 in) track pads)..................................................................................................2.59 m (8.5 in) (L) (with 700 mm (27.5 in) track pads).................................................................................................. 2.69 m (8.8 ft) (M) ......................................................................................................................................................0.44 m (17.3 in) (N) (2.10 m dipper) ............................................................................................................................. 7.61 m (24.9 ft) (N) (2.50 m dipper) ............................................................................................................................. 7.62 m (25.0 ft)

8-8

CHAPTER 8 - SPECIFICATIONS CX130B (MONOBLOC BOOM 3.00 M (9.8 FT) ARM IN TRANSPORT POSITION N E

D

C

B

A

F

M G H I

K J L CS00E557C

O 3

(A)......................................................................................................................................................... 2.82 m (9.3 ft) (B)......................................................................................................................................................... 2.79 m (9.2 ft) (C)......................................................................................................................................................... 2.82 m (9.3 ft) (D)......................................................................................................................................................... 2.54 m (8.3 ft) (E)......................................................................................................................................................... 2.13 m (7.0 ft) (F) ......................................................................................................................................................... 0.89 m (2.9 ft) (G) ........................................................................................................................................................ 2.79 m (9.2 ft) (H)....................................................................................................................................................... 3.50 m (11.5 ft) (I) (with dozer blade)........................................................................................................................... 4.02 m (13.2 ft) (J) ......................................................................................................................................................... 1.99 m (6.5 ft) (K) (standard track pads) ....................................................................................................................0.60 m (23.6 in) (L) with 500 mm (19.6 in) track pads .................................................................................................... 2.49 m (8.2 ft) (L) with 600 mm (23.6 in) track pads .................................................................................................... 2.59 m (8.5 ft) (L) with 700 mm (27.5 in) track pad ...................................................................................................... 2.69 m (8.8 ft) (M) ......................................................................................................................................................0.44 m (17.3 in) (N).......................................................................................................................................................... 7.64 m (25 ft) (O) (with dozer blade) ......................................................................................................................... 7.79 m (25.6 ft)

8-9

CHAPTER 8 - SPECIFICATIONS CX130B LC TYPE (MONOBLOC BOOM 3.00 M (9.8 FT) ARM IN TRANSPORT POSITION N E

D

C

B

A

F

M K J L

G H

CS00E557D

4 (A)......................................................................................................................................................... 2.82 m (9.3 ft) (B)......................................................................................................................................................... 2.79 m (9.2 ft) (C)......................................................................................................................................................... 2.82 m (9.3 ft) (D)......................................................................................................................................................... 2.54 m (8.3 ft) (E)......................................................................................................................................................... 2.13 m (7.0 ft) (F) ......................................................................................................................................................... 0.89 m (2.9 ft) (G) ......................................................................................................................................................... 3.04 m (10.0) (H)....................................................................................................................................................... 3.76 m (12.3 ft) (J) ......................................................................................................................................................... 1.99 m (6.5 ft) (K) (standard track pads) ....................................................................................................................0.60 m (23.6 in) (L) with 500 mm (19.6 in) track pads .................................................................................................... 2.49 m (8.2 ft) (L) with 600 mm (23.6 in) track pads .................................................................................................... 2.59 m (8.5 ft) (L) with 700 mm (27.5 in) track pad ...................................................................................................... 2.69 m (8.8 ft) (M) ......................................................................................................................................................0.44 m (17.3 in) (N).......................................................................................................................................................... 7.64 m (25 ft)

8-10

CHAPTER 8 - SPECIFICATIONS

WORKING RANGE 2.10 m

2.50 m

3.00 m

CS00K517B

Monobloc Boom

5 2.10 m (6.9 ft)

2.50 m (8.20 ft)

3.00 m (9.9)

(A) Maximum digging reach

7.96 m (26.1 ft)

8.31 m (27.3 ft)

8.77 m (28.8 ft)

(B) Maximum digging reach at ground level

7.81 m (25.6 ft)

8.17 m (26.8 ft)

8.64 m (28.3 ft)

(C) Maximum digging depth

5.15 m (16.9 ft)

5.54 m (18.2 ft)

6.05 m (19.8 ft)

(D) Maximum digging depth over a length of 2.44 m (8 ft)

4.91 m (16.1 ft)

5.33 m (17.5 ft)

5.87 m (19.3 ft)

(E) Maximum dump height

6.17 m (20.2 ft)

6.39 m (21 ft)

6.68 m (21.9 ft)

(F) Maximum working height

8.55 m (20.2 ft)

8.77 m (28.8 ft)

9.05 m (29.7 ft)

(G) Minimum attachment swing radius

2.36 m (7.7 ft)

2.34 m (7.7 ft)

2.66 m (8.7 ft)

(H) Maximum digging depth on a vertical face

4.60 m (15 ft)

4.95 m (16.2 ft)

5.35 m (17.6 ft)

2.44 m (8 ft)

2.44 m (8 ft)

2.44 m (8 ft)

(I) Maximum length of flat-bottomed trench

8-11

CHAPTER 8 - SPECIFICATIONS

QUICK COUPLER (optional) DIMENSIONS NEEDED TO FIT THE QUICK COUPLER Bucket pin diameter

65 mm (2.6 in)

Width between lugs

220 mm (8.7 in)

Minimum distance between bucket centres

355 mm (14 in)

Maximum distance between bucket centres

420 mm (16.5 in)

The quick coupler described in this manual is designed to be used with CASE buckets. This being said, other buckets may be used, provided the diameter of the pins and the width between the bucket lugs are modified to meet the dimensions needed to fit the quick coupler (pins, washers, bushings, etc.). See your authorized dealer.

WEIGHT 286 kg (630.5 lb) OVERALL DIMENSIONS

C

B

A CS00J503

6 A ......................................................................................................................................................... 860 mm (2.8 ft) B ......................................................................................................................................................... 480 mm (1.6 ft) C ....................................................................................................................................................... 390 mm (1.57 ft) NOTICE: The quick coupler described in this manual is designed to be used with CASE buckets. Other buckets may be used, provided the diameter of the pins and the width between the bucket lugs are modified to meet the dimensions needed to fit the quick coupler (pins, washers, bushings, etc.). See your authorized dealer.

8-12

CHAPTER 9 - INDEX

Chapter 9

INDEX A Air Conditioning Compressor ................................................... 6-14 Condenser ..................................................... 6-14 Air filter ..................................................... 5-34, 5-39 Air recycling ....................................................... 3-23 Anti-Theft Device ............................................... 3-21 Anti-theft protection indicator ............................. 3-16 Attachment failure .............................................. 4-23

Starting the Engine ..........................................4-6 Engine Service Engine Oil Level .............................................5-24 Oil Change and Filter Replacement ...............5-36 Engine Speed .......................................................4-6 Engine starting procedure ....................................4-8 Engine stopping procedure ................................4-11 Environment .......................................................5-11 Error code indicator ............................................3-16

B

F

Backhoe buckets ................................................. 8-6 Battery Cleaning .......................................................... 7-4 Fluid Level ....................................................... 7-4 Safety .............................................................. 7-3 Service ............................................................ 7-3 Vents ............................................................... 7-4 Before Operation Safety ...................................... 2-6 Bleeding ............................................................... 5-5 Booms ................................................................. 8-6 Burn Prevention ................................................. 2-10

Fan and alternator drive belt ...................... 5-25, 6-7 Filter Engine ............................................................5-36 Fluid and Lubricants .............................................5-8 Fluids and lubricants ..........................................5-10 Footrest ..............................................................3-32 Front storage box ...............................................3-37 Fuel Handling Precautions ...................................2-9 Fuel level indicator .............................................3-16 Fuel tank .............................................................3-38 Fuel tank filling pump .........................................3-42 Function and message display screen ...............3-16

C Cab ...................................................................... 8-5 Cab light ............................................................ 3-33 Cab Service ....................................................... 6-14 Checking the quick coupler latching hook opening ...

6-17 Coat hanger hook .............................................. 3-33

D Decals ................................................................ 2-13 Dippers ................................................................ 8-6 Dozer blade ......................................................... 8-6

E Electrical System ................................................. 7-3 Engine ................................................................. 8-3 Hourmeter ....................................................... 5-7 Engine coolant temperature indicator ................ 3-16 Engine Lubrication ............................................... 5-9 Engine Oil Selection ........................................ 5-9 Engine Oil Level ................................................ 5-24 Engine Oil Selection ............................................ 5-9 Engine Oil Type ................................................. 5-11 Engine Operation .......................................... 4-3, 4-6 Engine Speed .................................................. 4-6 Parking the Machine and Stopping the Engine 4-7

G General Information ..............................................1-1 General Safety .....................................................5-3 Grease points .....................................................5-16 Greasing the swing reduction gear .....................5-23 Greasing the turntable teeth ...............................5-23

H Hand Signals ......................................................2-24 Hardware torque inspection ..................... 5-33, 6-18 Hazardous Chemical Precautions ......................2-10 Hourmeter, Engine ...............................................5-7 Hydraulic fluid .....................................................5-10 Hydraulic fluid temperature indicator ..................3-16 Hydraulic system ..................................................8-3

I Identification Numbers Product Identification Number (P.I.N.) .............1-4 Inspecting and cleaning the machine ...................6-8 Instructions, General Safety .................................5-3 Instrument Panel ..................................................3-3

9-1

CHAPTER 9 - INDEX

L Lifting loads ....................................................... 4-15 Load holding control device ............................... 3-39 Lower panels ..................................................... 3-39 Lowering the attachment in the event machine failure 4-23 Lubrication/Filters/Fluids Engine Lubrication .......................................... 5-9 Fluid and Lubricants ........................................ 5-8

M Machine operation ............................................... 4-4 Machine Operation Safety ................................... 2-6 Machine overall dimensions ......................... 8-6, 8-7 Machine storage ................................................ 4-28 Machine travel ................................................... 4-12 Maintenance Precautions .................................... 2-9 Maintenance, 10 Hour ..................... 5-24, 5-25, 5-27 Message display screen .................................... 3-17

O Oil Change Engine ........................................................... 5-36 Oil Viscosity/Temperature Ranges ...................... 5-9 Operating in water ............................................. 4-20 Operating Instructions ......................................... 4-6 Operating Precautions ......................................... 2-7 Operating the backhoe bucket ........................... 4-21 Operating the machine in cold weather ............. 4-10 Operating the machine in hot weather ............... 4-10 Operator's compartment ...................................... 8-5 Operator's seat .................................................... 3-6 Owner, To The ..................................................... 1-1

P Parking the Machine and Stopping the Engine ... 4-7 Parking The Machine Safety ............................. 2-11 Personal Safety ................................................... 2-6 Plastic and Resin Parts ....................................... 5-7 Position of the operator’s compartment controls and accessories ................................................... 3-5

Q Quick coupler ..................................................... 8-12 Quick coupler locking/unlocking control ............ 3-33 Quick coupler tool lubrication ............................ 5-22

R Radiators and oil coolers ................................... 5-35 Releasing Hydraulic System Pressure ................ 5-4 Replacing a tooth on the backhoe bucket ......... 6-13 9-2

Run-In Period of a New Machine Track Shoe Bolts ..............................................4-3

S Safety devices ......................................................8-4 Safety Instructions, General .................................5-3 Safety, Battery ......................................................7-3 Safety, Decals, and Hand Signals Personal Safety ................................................2-6 Safety Rules .....................................................2-3 Utility Safety .....................................................2-4 Safety/Decals/Hand Signals Before Operation ..............................................2-6 Machine Operation ...........................................2-6 Parking The Machine .....................................2-11 Sides of the machine Right-hand, left-hand, front, and rear ...............1-3 Start Up After Storage ........................................4-28 Starting and Stopping Precautions .......................2-7 Starting the Engine ...............................................4-6 Starting the engine ...............................................4-8 Storage tray ........................................................3-35 Storing the machine ...........................................4-28 Sun shield ...........................................................3-35 Swing reduction gear ....................... 5-30, 5-31, 5-42

T Temperature control system ...............................3-22 To the Owner ........................................................1-1 Towing the machine ...........................................4-23 Track Shoe Bolts ..................................................4-3 Transmission component oil ...............................5-10 Travel control levers and pedals ........................3-31

U Undercarriage .......................................................8-4 Utility Safety Rules Message ................................2-4

W Walk-Around Inspecion ........................................4-6 Weight ..................................................................8-6 Working mode indicator ......................................3-16 Working range ....................................................8-11

Dealer’s stamp

CNH America LLC reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold.

Specifications, descriptions, and illustrative material herein are as accurate as known at time of publication, but are subject to change without notice.

Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your Case dealer.

Copyright © 2012 CNH America LLC. All Rights Reserved.

Case is a registered trademark of CNH America LLC. Racine Wisconsin 53404 U.S.A.