Case CX160B & CX180B Hydraulic Crawler Excavators Operator's Manual 87600995 - PDF DOWNLOAD

OM A4 Jaune Gabarit MM.qxd

31/10/2007

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CX160B and CX180B Hydraulic crawler excavators

Operator's Manual Lep 87600995 EN Replaces Lep 87624644 EN

CX160B and CX180B Hydraulic crawler excavators

Operator's Manual Lep 87600995 EN Replaces Lep 87624644 EN

THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH. The words Danger, Warning or Caution used on the safety decals have the following significance: • DANGER: Indicates an immediate hazardous situation that, if not avoided, could result in serious injury or even death. The colour associated with Danger is RED. • WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in serious injury. The colour associated with Warning is ORANGE. • CAUTION: Indicates a potentially hazardous situation that, if not avoided, may result in minor injury. It may also be used to alert against unsafe practices. The colour associated with Caution is YELLOW. Certain decals, in conformity with the ISO standard are in several parts. They must be interpreted as follows: • The upper panel indicates the nature of the danger.

• The lower panel indicates appropriate avoidance of the danger.

• Background colour is YELLOW. • Prohibition symbols such as

if used, are RED.

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

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

• Reads and understands ALL Safety Decals on the machine.

• Clears the area of other persons.

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

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

Reproduction or translation, even partial, is prohibited without written authorization from CNH France S.A. Company.

Copyright © 2007 CNH France S.A.

Lep 87600995 EN Issued February 2007 (Revised April 2007)

OPERATOR’S MANUAL CX160B CX180B

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QUICK REFERENCE SECTION GUIDE The Sections in this book are shown below.

1 - To the Owner 2 - Identification Numbers/Machine Components 3 - Safety/Decals/Hand Signals 4 - Controls/Instruments/Accessories 5 - Operating Instructions 6 - Servicing Intervals 7 - Lubrication/Filters/Fluids 8 - Maintenance/Adjustments 9 - Electrical System 10 - Storage 11 - Specifications 12 - Alphabetical Index

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TABLE OF CONTENTS SECTION 1 - TO THE OWNER .................................................................................................................. 1-1 CX160B and CX180B hydraulic crawler excavators ................................................................................ 1-1 Official documents .................................................................................................................................... 1-2 Right, left, front and rear of the machine .................................................................................................. 1-3 SECTION 2 - IDENTIFICATION NUMBERS/MACHINE COMPONENTS .................................................. 2-1 Type, serial number and year of manufacture of the machine ................................................................. 2-1 Description of the main components ........................................................................................................ 2-3 SECTION 3 - SAFETY/DECALS/HAND SIGNALS .................................................................................... 3-1 Safety instructions .................................................................................................................................... 3-1 Before using the machine ........................................................................................................................ 3-2 Operating the machine ............................................................................................................................. 3-3 Cab protection (F.O.P.S.) ......................................................................................................................... 3-4 Preventing risks caused by vibrations ...................................................................................................... 3-4 Quick coupler ........................................................................................................................................... 3-4 Safety area ............................................................................................................................................... 3-5 Parking the machine ................................................................................................................................ 3-5 Before using the hydraulic breaker .......................................................................................................... 3-6 Using the hydraulic breaker ..................................................................................................................... 3-6 Maintenance and adjustments ................................................................................................................. 3-7 Preventing fires or explosions .................................................................................................................. 3-8 Prevention of burns .................................................................................................................................. 3-9 Decals .................................................................................................................................................... 3-10 Hand signals .......................................................................................................................................... 3-22 SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES .................................................................... 4-1 Cab door .................................................................................................................................................. 4-1 Steps and access handles ....................................................................................................................... 4-2 Position of the operator’s compartment controls and accessories ........................................................... 4-3 Right-hand control arm ............................................................................................................................. 4-4 Front RH console ..................................................................................................................................... 4-6 Left-hand control arm ............................................................................................................................... 4-7 RH console ............................................................................................................................................... 4-9 Systems display and function control panel ........................................................................................... 4-10 Function and message display screen ................................................................................................... 4-12 Heating and ventilation or air conditioning controls ................................................................................ 4-15 Function cancellation lever and safety bar ............................................................................................. 4-19 Dipper and upperstructure swing left-hand control lever ........................................................................ 4-20 Boom and bucket right-hand control lever ............................................................................................. 4-20 Travel control levers and pedals ............................................................................................................ 4-21 Option pedals ......................................................................................................................................... 4-21 Articulated boom adjustment pedal (CX160B) ....................................................................................... 4-21 Offset-backhoe boom or high flow hydraulic circuit control pedal .......................................................... 4-22

TABLE OF CONTENTS Controls/Instruments/Accessories (continued) Low flow hydraulic circuit control pedal ..................................................................................................4-22 Adjustment and locking the option pedals ..............................................................................................4-23 Footrest ..................................................................................................................................................4-24 Cab light .................................................................................................................................................4-24 Coat hanger hook ...................................................................................................................................4-24 Fuse box .................................................................................................................................................4-25 Quick coupler locking and unlocking control switch ...............................................................................4-26 Roof curtain ............................................................................................................................................4-26 Roof hatch ..............................................................................................................................................4-26 Cab door sliding windows .......................................................................................................................4-27 Sun shield ...............................................................................................................................................4-27 Magazine rack ........................................................................................................................................4-27 Refrigerated compartment ......................................................................................................................4-27 Storage compartment .............................................................................................................................4-28 Cup holder ..............................................................................................................................................4-28 Operator's seat .......................................................................................................................................4-29 Windshield ..............................................................................................................................................4-33 Lower front window .................................................................................................................................4-34 Rear window (emergency exit) ...............................................................................................................4-34 Fuel tank .................................................................................................................................................4-35 Rear view mirrors ...................................................................................................................................4-36 Front storage box ...................................................................................................................................4-36 Side doors ..............................................................................................................................................4-37 Engine hood ...........................................................................................................................................4-38 Lower panels ..........................................................................................................................................4-38 Windshield washer reservoir ..................................................................................................................4-39 Rotary light cable ....................................................................................................................................4-39 Load handling eyes ................................................................................................................................4-40 Towing holes ..........................................................................................................................................4-41 Cab protection (F.O.P.S.) .......................................................................................................................4-41 Safety valves ..........................................................................................................................................4-42 Optional tool supply valves .....................................................................................................................4-42 Fuel tank filling pump ..............................................................................................................................4-43 SECTION 5 - OPERATING INSTRUCTIONS ............................................................................................. 5-1 Before using the machine .........................................................................................................................5-1 Operating the machine .............................................................................................................................5-2 Run-in period ............................................................................................................................................5-3 Anti-theft device ........................................................................................................................................5-4 Starting the engine ...................................................................................................................................5-7 Bringing the machine up to operating temperature ..................................................................................5-9

TABLE OF CONTENTS Operating instructions (continued) Engine operation .................................................................................................................................... 5-10 Stopping the engine ............................................................................................................................... 5-11 Operating the machine in cold weather .................................................................................................. 5-12 Operating the machine in hot weather ................................................................................................... 5-13 Machine operation .................................................................................................................................. 5-14 Machine travel ........................................................................................................................................ 5-15 Handling the machine ............................................................................................................................ 5-18 Load handling ......................................................................................................................................... 5-19 Handling the load with the quick coupler ................................................................................................ 5-20 Load handling limits charts ..................................................................................................................... 5-21 Operating the machine in water ............................................................................................................. 5-21 Operating the machine on sloping ground ............................................................................................. 5-22 Operating the backhoe bucket ............................................................................................................... 5-22 Quick coupler installation ....................................................................................................................... 5-23 Quick tool installation and removal ........................................................................................................ 5-23 Parking the machine .............................................................................................................................. 5-28 Towing the machine ............................................................................................................................... 5-30 Lowering the attachment in the event of a machine failure .................................................................... 5-31 Auxiliary hydraulic circuits ...................................................................................................................... 5-32 Transporting the machine ...................................................................................................................... 5-39 Handling the hydraulic breaker .............................................................................................................. 5-44 Hydraulic breaker breaking principles .................................................................................................... 5-44 Choice of the tools on the hydraulic breaker .......................................................................................... 5-45 Special conditions of use of the hydraulic breaker ................................................................................. 5-45 SECTION 6 - SERVICING INTERVALS ..................................................................................................... 6-1 Servicing instructions ............................................................................................................................... 6-1 Hourmeter ................................................................................................................................................ 6-2 Daily inspections ...................................................................................................................................... 6-2 Quick coupler servicing instructions ........................................................................................................ 6-4 Quick coupler incorrect functioning .......................................................................................................... 6-4 Hydraulic breaker servicing instructions ................................................................................................... 6-5 Intervals .................................................................................................................................................... 6-6 SECTION 7 - LUBRICATION/FILTERS/FLUIDS ........................................................................................ 7-1 Fluids and Lubricants ............................................................................................................................... 7-1 Environment ............................................................................................................................................. 7-4 Fluid and lubricant capacities and specifications ..................................................................................... 7-4 Grease points ........................................................................................................................................... 7-5 Levels ..................................................................................................................................................... 7-20 Engine .................................................................................................................................................... 7-22 Cooling system ....................................................................................................................................... 7-25

TABLE OF CONTENTS Lubrication/filters/fluids (continued) Fuel system ............................................................................................................................................7-28 Releasing pressure in the hydraulic system ...........................................................................................7-33 Hydraulic system ....................................................................................................................................7-35 Air filter ...................................................................................................................................................7-44 Swing reduction gear ..............................................................................................................................7-48 Travel reduction gears ............................................................................................................................7-50 SECTION 8 - MAINTENANCE/ADJUSTMENTS ........................................................................................ 8-1 Tracks .......................................................................................................................................................8-1 Track rollers and idler wheels ...................................................................................................................8-4 Radiators and oil coolers ..........................................................................................................................8-5 Fan and alternator drive belt .....................................................................................................................8-6 Adjustment of engine valve rocker clearances .........................................................................................8-7 Fuel tank filter ...........................................................................................................................................8-7 Cab protection (F.O.P.S.) .........................................................................................................................8-8 Fire extinguisher .......................................................................................................................................8-8 Welding on the machine ...........................................................................................................................8-9 Inspecting and cleaning the machine .......................................................................................................8-9 Checking for cylinder leakage ................................................................................................................8-10 Plastic and resin parts ............................................................................................................................8-10 Teeth and tooth tip wear limits ................................................................................................................8-11 Replacing a tooth on the backhoe bucket ..............................................................................................8-11 Replacing a backhoe bucket ..................................................................................................................8-12 Shimming the backhoe bucket ...............................................................................................................8-14 Replacing a tool on a hydraulic breaker .................................................................................................8-15 Replacing a tool bushing on a hydraulic breaker ....................................................................................8-17 Wear limits on a hydraulic breaker .........................................................................................................8-18 Replacing a hydraulic breaker ................................................................................................................8-20 Checking the quick coupler latching hook opening ................................................................................8-21 Air conditioning .......................................................................................................................................8-23 Engine troubleshooting ...........................................................................................................................8-27 Hardware torque inspection ....................................................................................................................8-29 SECTION 9 - ELECTRICAL SYSTEM ........................................................................................................ 9-1 Fuses ........................................................................................................................................................9-1 Batteries ...................................................................................................................................................9-3 Alternator ..................................................................................................................................................9-7 Starter motor .............................................................................................................................................9-7 Replacing a bulb .......................................................................................................................................9-8 SECTION 10 - STORAGE ......................................................................................................................... 10-1 Storing the machine ................................................................................................................................10-1

TABLE OF CONTENTS SECTION 11 - SPECIFICATIONS ............................................................................................................ 11-1 Engine .................................................................................................................................................... 11-1 Hydraulic system .................................................................................................................................... 11-1 Undercarriage ........................................................................................................................................ 11-2 Safety devices ........................................................................................................................................ 11-2 Operator’s compartment ........................................................................................................................ 11-3 Noise levels ............................................................................................................................................ 11-3 Vibration level inside the cab ................................................................................................................. 11-3 Cab ......................................................................................................................................................... 11-3 Weights .................................................................................................................................................. 11-4 Booms .................................................................................................................................................... 11-4 Dippers ................................................................................................................................................... 11-4 Backhoe buckets .................................................................................................................................... 11-4 Machine overall dimensions ................................................................................................................... 11-5 Working range ........................................................................................................................................ 11-8 Hydraulic breakers ............................................................................................................................... 11-11 Quick coupler ....................................................................................................................................... 11-15 SECTION 12 - ALPHABETICAL INDEX .................................................................................................. 12-1

TABLE OF CONTENTS

NOTES

SECTION 1

4

TO THE OWNER CX160B and CX180B HYDRAULIC CRAWLER EXCAVATORS

CT07A059

1 Model shown: CX160B Dealer's Stamp

CNH France S.A. 16-18 rue des Rochettes 91150 MORIGNY - CHAMPIGNY FRANCE

1-1

SECTION 1 - TO THE OWNER Your machine has been designed and built to the highest standards of quality. It conforms to all current safety regulations. See "Official documents". However, the risk of accidents can never be completely excluded. That is why it is essential to observe elementary safety rules and precautions.

Always keep this manual in the operator's compartment (in the seat back, behind the operator's seat).

Make sure it is always complete and in good condition.

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

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

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

The standard attachments and tools of this machine are designed to carry out all kinds of earthmoving and rehandling operations. If you want to use this machine to handle a load (pipes, culverts, formwork, etc.), make sure that it is designed to carry out this kind of work.

For this type of application, the machine must be equipped with safety valves, an overload indicator, a load handling chart corresponding to the type of machine and its attachment and a load fixing point. All legal requirements must also be strictly observed.

OFFICIAL DOCUMENTS

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.

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

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: 1. That the operator has received the necessary training on how to operate the machine correctly and safely in one of our training centres or from an approved organization.

2. That the operator has read and understood the instructions given in this manual.

1-2

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

A type approval certificate - Noise level (2000/14/EC) (separate copy of the certificate or on the back of the "CE" conformity declaration) A "CE" certificate of conformity: - For a new construction equipment machine, series produced to a type approved design, designed and manufactured in accordance with the requirements of European directive 98/37/EC, concerning machine safety and mainly: 1 - The following directives: - 89/336/EC: Electromagnetic compatibility - 2000/14/EC: Noise level 2 - The following European standards: - EN 474-1: Safety - General requirements - EN 474-5: Safety - Hydraulic excavators including load handling IMPORTANT: An original of this "CE" certificate is supplied with each machine and must be kept carefully by the owner.

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

SECTION 1 - TO THE OWNER RIGHT, LEFT, FRONT AND REAR OF THE MACHINE The terms "Right", "Left", "Front" and "Rear" are used in this manual to indicate the sides as they are seen from the operator's seat when the cab is over the idler wheels.

A F

F

D

C

E

E

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

A. B. C. D. E. F.

FRONT REAR RH SIDE LH SIDE TRAVEL MOTORS IDLER WHEELS

CS06K000

B 2

1-3

SECTION 1 - TO THE OWNER

NOTES

1-4

SECTION 2

4

IDENTIFICATION NUMBERS/MACHINE COMPONENTS TYPE, SERIAL NUMBER AND YEAR OF MANUFACTURE OF THE MACHINE When ordering parts, obtaining information or assistance, always supply your CASE dealer with the type and serial number of your machine or accessories.

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

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

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

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

1

2

3

CT04A171B

1 ENGINE Make and type ................................ ISUZU AI - 4JJ1X Serial number................................................................. ........................................................................................

CT04D014B

2

2-1

SECTION 2 - IDENTIFICATION NUMBERS/MACHINE COMPONENTS COMPONENT SERIAL NUMBERS Hydraulic pump .............................................................. ........................................................................................

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

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

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

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

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

HYDRAULIC BREAKER (optional)

4

1

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

2

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

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

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

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

5

(6) Date of manufacture.................................................

(7) Operating flow...........................................................

CT04K001A

7

6

3 3

QUICK COUPLER (optional)

4

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

5

1

2

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

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

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

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

(6) Date of manufacture.................................................

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

CS97A032C

7

6

3 4

2-2

SECTION 2 - IDENTIFICATION NUMBERS/MACHINE COMPONENTS DESCRIPTION OF THE MAIN COMPONENTS The CX160B and CX180B are totally hydraulic machines. They consist of an undercarriage fitted with tracks and a turntable bearing which supports the upperstructure frame. The upperstructure frame supports the attachment, at the front end of the machine, plus the engine, hydraulics and cab. When the operator works the controls, the engine-driven pump delivers hydraulic fluid to the control valves. The control valves distribute the hydraulic fluid to the various cylinders and hydraulic motors employed. A cooling system maintains the hydraulic fluid at normal operating temperature.

12

11

13

10

14

24

15

9 25 16

26

17 18 7 6

19

8 20 1 22

21

23 4

3

2

5 CT07A016

5 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

Backhoe bucket Connecting rod Yokes Backhoe bucket cylinder Dipper Dipper cylinder Boom Boom cylinders Swing reduction gear Fuel tank Hydraulic reservoir Control valve Hydraulic pump

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

Engine compartment Counterweight Air filter Batteries Tracks Travel reduction gears Lower rollers Upper rollers Tension shock absorbers Idler wheels Cab/Operator's compartment Turntable bearing Hydraulic swivel

2-3

SECTION 2 - IDENTIFICATION NUMBERS/MACHINE COMPONENTS

NOTES

2-4

SECTION 3

26

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

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

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

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

Whatever type of work is being done (earthmoving, handling, etc.), the safety measures for private or public work-sites are those which conform to current regulations in the country concerned, or the type of operation concerned (for example: mining, quarrying, underground work).

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

Always keep this manual in the location provided for that purpose (behind the operator’s seat). Make sure it is always complete and in good condition. If you wish to obtain extra copies, or copies in languages other than that of the country of use, consult your CASE Dealer.

CT06M020

1

3-1

SECTION 3 - SAFETY/DECALS/HAND SIGNALS BEFORE USING THE MACHINE 1.

2.

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

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

3.

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

4.

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

5.

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

6.

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

7.

Remove any obstructions which hinder visibility.

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

8.

Make sure the windshield wiper works correctly.

9.

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

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

3-2

11. Before any travel operation, make sure that the doors and hoods are properly latched.

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

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

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

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

16. Be sure you know the position and function of each control. Incorrect operation of the controls can cause serious injuries.

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

18. Keep away from dangerous areas such as ditches, overhangs, rocky areas, etc. Make a survey of the work-site and determine the possible dangers before using the machine.

19. Before moving the machine to work in a new area, walk around to determine all possible causes of accidents there. Holes, obstacles, debris and other danger risks in the working area can cause serious injury.

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

21. Check the fastening of the main components: counterweight, turntable bearing and operator's compartment. In the event of problems, contact your CASE Dealer.

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

SECTION 3 - SAFETY/DECALS/HAND SIGNALS 23. Work out a means of convenient escape from the machine (emergency exit via the windshield or the rear window glass) in the event of the cab door being jammed or the machine turning over.

5.

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

6.

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

More than 57 000 volts: 5 metres.

7.

Study the position of any existing pipelines or conduits before starting work. Electrical cables, gas and water pipes and other underground installations can cause serious injury.

8.

Always make allowance for working conditions (sloping or rough ground), the site and weather conditions when driving the machine.

9.

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

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

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

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

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

QUICK COUPLER (optional) 1.

It is mandatory for the switch to be in the locked position when operating the machine.

2.

Every day, check that the locking bar functions correctly and that it is not fouled by foreign matter.

Clean the locking system if necessary.

3.

If you are obliged to use the quick coupler with buckets not manufactured by CASE, make sure the diameter of the pins and the width between the bucket lugs meet the dimensions needed to fit the quick coupler (pins, washers, bushings, etc.).

Consult your CASE Dealer.

OPERATING THE MACHINE 1.

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

2.

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

3.

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

4.

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

10. Operate all controls gradually to ensure smooth machine operation.

11. 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.

12. It is forbidden to use the machine to carry out tasks other than those for which it is intended.

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

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

14. In some configurations, the working range of the attachment allows the tool to interfere with the machine. Always maintain a safe minimum distance between the tool and the machine (swaying of the tool or incorrect operation).

15. To access or exit the operator’s compartment, the LH control arm must be in the raised position.

Never forget this basic requirement.

3-3

SECTION 3 - SAFETY/DECALS/HAND SIGNALS 16. Never leave the operator's compartment while the engine is running.

PREVENTING RISKS CAUSED BY VIBRATIONS

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

The machine's vibration affects the comfort and in some cases the health and safety of the operator. To reduce vibration risks to a minimum:

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

1.

Make sure that the machine, the equipment and the tool are suitable for the work to be carried out.

2.

Make sure that the machine is in good condition and that servicing intervals are complied with.

3.

Check the track tension adjustment and the play in equipment linkages.

20. In the event of an operating problem or failure, move the machine to a safe place, lower the attachment to the ground, shut down the engine and remove the starter switch key. Locate the problem, report it if necessary and take the necessary steps to warn others not to attempt to operate the machine.

4.

Make sure that the operator's seat and is adjustment controls are in good condition and then adjust the seat to suit the operator's size and weight. The operator’s seat complies with the ISO 7096, 2000 standard, EM 3 or EM 4 class (according to the model).

21. Before tilting the seat back forward, it is mandatory to raise the armrests to avoid any accidental operation of the control levers.

1.

Operate all controls gradually to ensure smooth machine operation.

2.

Modify the machine's operation to suit the working conditions.

3.

During travel, adjust the machine's speed, reducing it if necessary.

4.

Make sure that the machine's operating radius is in good condition, and free of obstacles and holes.

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

CAB PROTECTION (F.O.P.S.) (optional) 1.

Never try to weld or straighten up the protective structure (F.O.P.S.).

2.

Do not modify the protective structure (F.O.P.S.) in any way. Any modification, such as welding, drilling, cutting, addition of accessories, as well as damage suffered following an impact reduces the protection that it provides. Replace the protective structure (F.O.P.S.) if it has suffered an impact and do not attempt to repair it.

3.

3-4

Incorrect inspection or service work of the protective structure (F.O.P.S.) may lead to serious injury.

Carry out inspection operations of the protective structure (F.O.P.S.) given in this manual. If the protective structure (F.O.P.S.) or its components need to be replaced, use only those parts that are listed in the spare parts catalogue corresponding to your machine.

During work:

QUICK COUPLER (optional) 1.

Never place the control switch in the unlocked position when the machine is working.

2.

Each time a bucket is installed on the quick coupler, close the bucket and raise the attachment so as to be able to make a visual check that the bucket pin is correctly engaged in the latching hook.

3.

The quick coupler modifies the working range of the machine. In certain attachment positions the tool may foul the machine. Always leave a safety distance.

4.

Never carry out load handling using the front or rear anchoring points used to install the tool on the quick coupler.

5.

Never put your hands inside the quick coupler and never attempt to adjust or repair the quick coupler if the engine is running.

SECTION 3 - SAFETY/DECALS/HAND SIGNALS SAFETY AREA The safety area is the space necessary for the machine to operate at the maximum range of the tool and at full swing (360°) plus 2 metres.

1.

Working area.

2.

Safety area.

2

1 CS97M019

2

PARKING THE MACHINE When parking the machine, proceed as follows: 1. Position the machine on flat, level ground, away from soft ground, excavations or poorly shored cavities.

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

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

4. You must place the function cancellation lever in the central position (safety bar in inward position) before leaving the operator’s compartment.

5. Lock the cab door.

6. Make sure that the hoods and doors are properly latched.

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

3-5

SECTION 3 - SAFETY/DECALS/HAND SIGNALS BEFORE USING THE HYDRAULIC BREAKER (optional) 1.

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

2.

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

3.

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

4.

5.

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

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

USING THE HYDRAULIC BREAKER (optional) 1.

Protect yourself and the vicinity from flying chips of rock.

2.

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

3.

Move everybody away before operating the hydraulic breaker.

4.

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

5.

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

6.

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

7.

Do not operate the hydraulic breaker if the tool is in contact with some part of the machine.

8.

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

3-6

9.

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

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

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

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

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

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

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

16. When breaking concrete, hard or frozen ground, never strike and pry with the tool at the same time.

The tool may snap off. Bending may be caused by stones inside hard or frozen ground. Be careful and stop striking if you encounter sudden resistance under the tool.

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

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

SECTION 3 - SAFETY/DECALS/HAND SIGNALS MAINTENANCE AND ADJUSTMENTS 1.

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

2.

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

3.

Release pressure completely in the hydraulic system before disconnecting the hydraulic piping.

Hydraulic oil escaping under pressure can cause serious injury.

4.

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

5.

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

6.

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

7.

If the attachment is raised or if the machine moves without an operator, serious injury can result. Before carrying out maintenance on this machine, proceed as follows: 1. Park the machine on flat, level ground.

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

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

4. Lock the tracks to prevent any machine movement.

8.

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

9.

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

10. Pressurized hydraulic fluid or grease which penetrates the skin can cause serious injury. Take the necessary safety precautions (safety clothing and protection for face and hands) to avoid such risks.

Also, before using these products, read the manufacturer's instructions concerning their use. If hydraulic fluid penetrates the skin, call a doctor immediately.

11. The pressure in the track tension cylinders is high.

Follow the procedure described in this manual carefully for increasing or reducing track tension.

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

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

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

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

15. Periodically inspect the fastening of the main components, as part of the machine maintenance programme: counterweight, turntable bearing and operator's compartment. In the event of problems, contact your CASE Dealer.

3-7

SECTION 3 - SAFETY/DECALS/HAND SIGNALS 16. If the accumulator is not functioning correctly, see your CASE Dealer. Never try to carry out any servicing operation on the accumulator. If this instruction is not followed serious injury can result.

PREVENTING FIRES OR EXPLOSIONS 1.

Engine fuel can cause an explosion or a fire.

- Never refuel when the engine is running.

- Never smoke while refuelling.

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

2.

Always use a non-inflammable solvent for cleaning parts.

3.

A spark or a naked light can cause the hydrogen in a battery to explode. To avoid all risk of explosion, be sure to follow the instructions below: - When disconnecting battery cables, always disconnect the negative cable (-) first.

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

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

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

4.

Always store batteries in a safe place, out of the reach of children.

5.

Sparks can fly from the electrical system or the engine exhaust. Before running the machine in an area where there may be inflammable gasses, make sure there is adequate ventilation.

6.

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

7.

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

8.

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

17. The accumulator is charged with nitrogen under high pressure. Do not weld or allow flames to come near to the accumulator.

18. There is high pressure fuel in the feed pipe when the engine is running and immediately after it has been shut down. Wait for 2 minutes after engine shut down before you do any maintenance or inspections to allow the pressure to drop in the pipe.

19. High voltage is charged to the controller and/or the injector when the engine is running and immediately after it has been shut down.

Do not touch the controller or the injector.

If it is necessary to touch them for maintenance purposes, consult your CASE Dealer.

HYDRAULIC BREAKER (optional) 1.

2.

The hydraulic breaker incorporates one accumulator. This accumulator remain constantly under pressure, even when the hydraulic breaker is removed from the machine. Never carry out any service work on the accumulator. Any service work on the accumulator must be carried out by your CASE Dealer.

Before carrying out any service work on the hydraulic breaker, make sure all pressure has been correctly released, in order to avoid any uncontrolled movement.

QUICK COUPLER (optional) 1.

3-8

Every day, check that the locking bar functions correctly and that it is not fouled by foreign matter.

Clean the locking system if necessary.

SECTION 3 - SAFETY/DECALS/HAND SIGNALS PREVENTION OF BURNS 1.

The electrolyte in the batteries can cause serious burns. The battery contains sulphuric acid. Avoid contact with skin, eyes and clothing.

Antidote: EXTERNAL: rinse thoroughly with water and remove soiled clothes.

INTERNAL: do not induce vomiting. Rinse the mouth out with water. Seek medical advice.

EYES: rinse thoroughly with water for 15 minutes and seek medical advice.

2.

When battery electrolyte freezes it can explode if you try to charge the battery or start up the engine with a booster battery. To prevent the electrolyte from freezing, always keep the battery fully charged.

3.

The battery produces explosive gases. Keep all naked flames, sparks and cigarettes away.

Ensure adequate ventilation when charging batteries or when using in a confined place. Always protect your eyes when working near the battery.

4.

Boiling coolant solution can spray out if the radiator cap is removed while the system is still hot.

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

5.

Never touch battery terminals with the hands as electrolysis can take place within the human body and damage vital organs.

3-9

SECTION 3 - SAFETY/DECALS/HAND SIGNALS DECALS

!

WARNING

!

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

!

WARNING

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 on the machine, consult the spare parts catalogue.

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.

Position of decals See the "Illustration of decals" for the functions of decals.

When replacing a decal, make sure it is located as shown below.

1

2

7 6

3

KHP11600-00

KHP12540-00

4 5

KHP11370-00

24V

KHP12151-00

ACTIVATE :A FUNCTION

AUX.CONTROL

ACTIVATE :B FUNCTION

KHP1484-00

KHP11590 00 KHP11590-00

CT06K001

3

3-10

SECTION 3 - SAFETY/DECALS/HAND SIGNALS

18

9

8

10 10

12

11

21

25

23 24

17 15 19

22

16 14 13 20

CT07A017

4

Illustration of decals TABLE OF SAFETY PRECAUTIONS Part number: KHP12151

1

CT06K003

A

F

B

E

C

D 5 3-11

SECTION 3 - SAFETY/DECALS/HAND SIGNALS TOOL INTERFERENCE This decal draws attention to the fact that, in certain positions, there can be interference of the tool between the attachment and the operator's compartment.

Always observe a minimum safety distance between the tool and the operator's compartment (in case of swinging or accidental movements).

A

CT05K003

6 DANGER ELECTRIC LINE This decal shows that work near overhead high-voltage electric lines must not be done without checking beforehand that all necessary measures have been taken to respect the minimum distances

B

CT06K004

7 SEAT BELT This decal shows that the seat belt must always be fastened so that you don’t get ejected if the machine turns over.

C

CT06K005

8 OPERATOR’S MANUAL This decal shows that you must read this manual before using the machine.

D

CS96D164

9 3-12

SECTION 3 - SAFETY/DECALS/HAND SIGNALS MAINTENANCE OR INSPECTION This decal shows that the engine must be stopped and the starter key switch removed during maintenance or inspection of the machine.

E

CT06K006

10 PARKING THE MACHINE This decal shows that, before leaving the operator’s compartment, the bucket must be lowered to the ground, the function cancellation lever must be activated, the engine stopped and the starter key switch removed in order to prevent any movement of the machine.

F

CT06K007

11 FUNCTION OF THE CONTROL LEVERS

2

Part number: KHP11370 This decal shows the function of the left-hand and right-hand control levers.

KHP11370-00

CT06K008

12 WINDSHIELD LOCKING Part number: KHP12540

3

This decal shows that the windshield must be correctly locked in open position, in order to prevent it from tipping.

CT06K009

13 3-13

SECTION 3 - SAFETY/DECALS/HAND SIGNALS FUNCTION OF THE LEVERS AND PEDALS

4

Part number: KHP1498 (standard) KHP1484 (with right-hand option) KHP1510 (with left-hand option) KHP1511 (with right and left-hand options) This decal shows the function of the travel control levers and pedals.

CS00E529

14 CIGARETTE LIGHTER SOCKET (24 volts) Part number: KHP11590

5

This decal shows the location and the voltage of the cigarette lighter socket. It is strictly prohibited to connect devices of a different voltage.

24V

KHP11590-00

CT06K010

15 EMERGENCY EXIT Part number: KHP11600

6

This decal shows the location and way how to use the emergency exit (rear window).

KHP11600-00

CT06K011

16 POCKET FOR MAXIMUM HANDLING LIMITS TABLE

7 Part number: G4647501 This pocket is provided for the table showing maximum handling limits corresponding to the attachment installed on the machine.

3-14

SECTION 3 - SAFETY/DECALS/HAND SIGNALS IT IS FORBIDDEN TO STAND WITHIN THE WORKING RANGE OF THE UPPERSTRUCTURE

8

Part number: K4051597 This decal reminds the operator not to allow anyone to stand within the working range of the upperstructure while the engine is running (risk of being crushed).

CS95M062

17 IT IS FORBIDDEN TO STAND WITHIN THE WORKING RANGE OF THE ATTACHMENT

9

Part number: L4051598 This decal reminds the operator not to allow anyone to stand within the working range of the attachment while the engine is running (risk of being crushed).

CS95M063

18 SLINGING POINTS Part number: H7947565

10

This decal shows where to attach slings when handling the excavator. Never use any other slinging points apart from those designated by this decal.

PDE0768

19 HYDRAULIC RESERVOIR Part number: 168104A1

11

This decal shows the location of the hydraulic reservoir.

CS96D166

20 3-15

SECTION 3 - SAFETY/DECALS/HAND SIGNALS FUEL TANK Part number: KHP11700

12

This decal shows the location of the fuel tank and that suitable fuel must be used.

CT06B013

21 ENGINE HOOD Part number: 168109A1

13

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

CS98B169

22 ENGINE HOOD Part number: KHP12230

14

This decal shows that it is prohibited to climb onto the engine hood (risk of falling).

KHP12230-A

CT06K012

23 STARTING THE ENGINE Part number: 168110A1

15

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

CS96D163

24 3-16

SECTION 3 - SAFETY/DECALS/HAND SIGNALS RISK OF FALLING Part number: KHP12220

16

This decal shows that a safety distance must be maintained during movements on the upperstructure frame.

KHP12220-00

CT06K013

25 EXHAUST Part number: 168112A1

17

This decal warns that one must never touch the silencer when it is still hot.

CS96C040

26 RADIATOR Part number: 168101A1

18

This decal warns that the radiator must never be touched and that the radiator cap must never be removed while the cooling system is still hot. Wait for the system to cool down before carrying out any operation.

CS96C179

27 FAN BELT Part number: 168111A1

19

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

CS96C038

28 3-17

SECTION 3 - SAFETY/DECALS/HAND SIGNALS INTERCOOLER (Intermediate cooler) Part number: KHP12690

20

This decal warns that one must never touch the cooler when it is still hot.

CT07A018

KHP12690-00

29 BATTERIES Part number: KHP12240

21

This decal shows that it is necessary to consult this manual before handling the batteries.

CT06K014

KHP12240-00

30 NOISE LEVEL Part number: KHP1760

22

This decal shows the value of the noise level in decibels outside the machine guaranteed by the manufacturer in accordance with the European directive 2000/14/EC.

CS02E580

31

3-18

SECTION 3 - SAFETY/DECALS/HAND SIGNALS FILLING PUMP (if equipped) Part number: L2651565

23

This decal shows that this manual should be consulted to fill the fuel tank using the filling pump.

PDF0357

32 SERVICING TABLE Part number: Monobloc boom: KLP10351 Articulated boom: KLP10461

24

" " ( " CHECK

J

L LY

A

J

This decal shows the servicing points and intervals.

J

J

J

J

:

KRP11512

J

J

-42 $

33 ACCUMULATOR This decal warns that the accumulator is filled with gas under high pressure and that one must not bring a flame or weld close to the accumulator. For any service work, consult your CASE Dealer.

25

CT07A056

34 ARTICULATED BOOM TOOL INTERFERENCE (CX160B) Part number: KHP10960 This decal draws attention to the fact that, in certain positions, there can be interference between the tool and the operator's compartment. Always maintain a safe minimum distance between the tool and the operator's compartment.

KHP10960-00

CT07A053

35 3-19

SECTION 3 - SAFETY/DECALS/HAND SIGNALS QUICK COUPLER (optional) This decal shows the precautions to be taken to ensure that the implement is correctly installed on the quick coupler.

CS01B501

36 HYDRAULIC BREAKER (optional) This decal shows that it is necessary to consult this manual in order to use the hydraulic breaker and the machine correctly.

CT04K032

37 These decals show the location of the accumulators, they indicate that the accumulators are pressurised; for any service work, contact your CASE Dealer.

CT04K005

38

3-20

SECTION 3 - SAFETY/DECALS/HAND SIGNALS This decal shows that there is a risk of flying chips when using the hydraulic hammer.

CT04K006

39 This decal shows that noise protection must be worn when operating the hydraulic hammer.

CT04K031

40 These decals show the hydraulic hammer greasing points.

CT04K004

41

3-21

SECTION 3 - SAFETY/DECALS/HAND SIGNALS HAND SIGNALS When operating the machine, never attempt to carry out tasks calling for fine control or working in areas where visibility is poor or impaired without seeking the assistance of a signalman. Make perfectly sure that you and the signalman understand the signals to be used.

START THE ENGINE

COME TO ME Wave hands back and forth (palms inwards).

PDE0002A

42

PDE0003A

SHUT DOWN THE ENGINE

44 MOVE AWAY FROM ME Wave hands back and forth (palms outwards).

PDE0002

43 PDE0003

45

3-22

SECTION 3 - SAFETY/DECALS/HAND SIGNALS EMERGENCY STOP

GO THIS FAR

Wave hands back and forth.

PDE0004A

46

PDE0005

ALL STOP AND HOLD

49 RAISE LOAD OR TOOL

PDE0004

47

PDE0006A

STOP

50 LOWER LOAD OR TOOL

Wave one hand back and forth.

PDE0005A

PDE0006

48

51

3-23

SECTION 3 - SAFETY/DECALS/HAND SIGNALS TURN MACHINE RIGHT (swing load right)

SLOWLY RAISE THE LOAD OR TOOL

To stop movement, stop moving hand and clench fist.

PDE0007A

52

PDE0008

SLOWLY LOWER THE LOAD OR TOOL

55 RAISE TOOL

PDE0007

53

PDE0009A

TURN MACHINE LEFT (swing load left)

56

To stop movement, stop moving hand and clench fist.

PDE0008A

PDE0009

54

3-24

LOWER TOOL

57

SECTION 3 - SAFETY/DECALS/HAND SIGNALS LIFT BOOM

EXTEND DIPPER

PDE0010A

PDE0011

58 LOWER BOOM

61 FILL TOOL

PDE0010

PDE0012A

59 RETRACT DIPPER

62 EMPTY TOOL

PDE0011A

PDE0012

60

63

3-25

SECTION 3 - SAFETY/DECALS/HAND SIGNALS

NOTES

3-26

SECTION 4

44

CONTROLS/INSTRUMENTS/ACCESSORIES CAB DOOR To open the door, use the handle (1) from the outside and use the handle (2) from the inside.

1

CT06K017

1

2

CT06K018

2 The door can be latched in completely open position.

To unlatch the door, tilt the lever (3) downwards.

!

WARNING

!

3

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

!

WARNING

!

When seated in the operator’s compartment, with the engine running, make sure that you do not to operate the LH control lever inadvertently when unlocking the door. To prevent any incident, place the function cancellation lever in the centre position.

See "Function cancellation lever and safety bar".

!

WARNING

CT06K019

3

!

Be careful not to get your hand, clothes, etc. caught in the door when closing it.

4-1

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES STEPS AND ACCESS HANDLES 1

1

2 CT07A057

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

!

WARNING

1

!

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

2 2

!

WARNING

!

When alighting from or getting into the operator’s compartment, never use the LH control arm or the control levers for assistance.

!

WARNING

!

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

!

WARNING

!

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

4-2

CT07A058

5

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES POSITION OF THE OPERATOR’S COMPARTMENT CONTROLS AND ACCESSORIES

!

WARNING

!

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

1 14

13 12 7

10 15

11

9

2

8

5 7 6

16

3

4

CT06K016

6 1.

2.

3.

4.

5.

6.

7.

8.

9.

Operator's seat LH control arm Function cancellation lever Safety bar Dipper and upperstructure swing left-hand control lever 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

4-3

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES RIGHT-HAND CONTROL ARM

6

1

5 9 9A

7

3 4 8 7

2

CT06K022A

7 1. STARTER SWITCH This switch has four positions, "ON" (contact), "START" (engine ignition), "OFF" (engine shutdown) and "ACC" (accessory current supply). See "Starting the engine" in section 5.

IMPORTANT: When the starter switch key is in "ON" (contact) position, if the anti-theft device has been programmed, then it will be necessary to enter the code. The message "PASSWORD" will be displayed. See "Anti-theft protection" in section 5.

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

2. ENGINE ACCELERATION BUTTON AND WORKING MODE SELECTOR This button enables an increase or reduction in the engine speed. This button is coupled with the three working mode selector. Mode "A" (automatic) when the energy output has priority. In this mode, the balance between the speed and energy output is controlled for each movement of the controls. Mode "H" for difficult excavation work or if the load increases, and mode "SP" when the output has priority. Each selected mode (A, H or SP) is displayed on the screen, see "Function and message display screen" (item 4).

NOTE: To select the "SP" mode, operate the indexing pin while rotating the acceleration button to the right.

4-4

NOTE: If there is no change in engine speed, press and release the engine automatic idle speed selector (see item 3).

3. ENGINE IDLE SPEED SELECTOR This control 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 "Engine idling" icon will appear on the systems display panel. When the control is pressed and released once more the engine will revert to its original speed and the icon on the systems display panel will disappear.

4. 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 it in this position, tilt the control arm to the required position and then release the lever.

!

WARNING

!

The adjustment of the control arm must be done with the engine stopped.

5. ROTARY LIGHT CONTROL This control is used to turn the rotary light on or off (not supplied). Press "ON" (run), the rotary light and the indicator lamp on the switch come on. Press "OFF" (stop), to turn off the rotary light.

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES 6. OVERLOAD INDICATOR SWITCH This control is to be used during load handling. Place the switch in the "ON" position. If the load to be lifted exceeds the authorized limit, the audible alarm will sound. In the "OFF" position the switch is non-operational. See "Load handling" in section 5.

IMPORTANT: Before undertaking any load handling operations, place the switch in the "ON" position.

7. OPTION CONTROL (if equipped) 8. CAB RADIO COMPARTMENT This pre-equipped compartment is provided for installing a 12 volts car radio (optional).

To operate the cab radio, consult the instruction manual supplied.

9. ARTICULATED BOOM (if equipped) OR HYDRAULIC BREAKER OR HIGH FLOW CONTROL (CX160B) This is a two-position control: the "OFF" position is used to control optional accessories such as a grab, shears, etc. The "ON" position is used to control boom adjustment via the articulated boom or high flow hydraulic circuit adjustment pedal. See "Auxiliary hydraulic systems" in section 5.

9A.OFFSET-BACKHOE BOOM (if equipped) OR HYDRAULIC BREAKER OR HIGH FLOW CONTROL This is a two-position control: the "OFF" position is used to control optional accessories such as a grab, shears, etc. The "ON" position is used to control boom movement via the offset-backhoe boom or high flow hydraulic circuit adjustment pedal. See "Auxiliary hydraulic systems" in section 5.

4-5

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES FRONT RH CONSOLE 1.

TEMPERATURE PROBE

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

1

For maintenance of the air conditioning circuit components, see "Air conditioning" in section 8.

2.

CLOCK

Adjusting the clock: Every time the "H" key is pressed, the hours display is incremented by one unit (1 to 12).

Every time the "M" key is pressed, the minutes display is incremented by one unit (0 to 59).

Pressing the "M" key continuously resets the clock.

3.

2 H

M

3 3

AIR VENTS

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

IMPORTANT: The air vents must always be open when the air conditioning is in use.

4.

STORAGE TRAY

5.

CIGARETTE LIGHTER (24 volts)

4 5

The key switch being in the "ON" position, press then release the cigarette lighter.

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

!

WARNING

!

If the cigarette lighter does not move outwards 30 seconds after pressing it in, pull it out manually, since otherwise the electrical circuit could be damaged; see your CASE dealer.

Once the cigarette lighter has been removed from its socket, the latter can be used as a 24 volts electrical socket.

4-6

CT06K023

8

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES LEFT-HAND CONTROL ARM

2

6

4

8 5

3 1

6

7

CT06K0024

9 1. ARM ANGLE ADJUSTMENT LEVER This lever is used to adjust the control arm tilt in four different positions to suit the operator. Pull the lever to the right and hold it in this position, select the required position and then release the lever.

When the lever is lowered, the control arm is automatically placed in the selected position.

!

WARNING

!

The adjustment of the control arm must be done with the engine stopped.

2. FUNCTION CANCELLATION LEVER AND LIFTING THE CONTROL ARM This lever is used to cancel the functions without having to raise the control arm. It is also used to operate the safety bar (3). See "Function cancellation lever and safety bar". This lever also makes it possible to raise the control arm completely, which also cancels all machine functions.

3. SAFETY BAR The purpose of this safety bar is to prevent the operator leaving the operator’s compartment without first operating the function cancellation lever (2). See "Function cancellation lever and safety bar".

4. HORN To sound the horn, press the end of the LH control lever.

IMPORTANT: Always sound the horn before operating the machine.

5. ASHTRAY Pull the ashtray upwards to empty it.

6. OPTION CONTROL (if equipped) 7. CAR RADIO MUTE CONTROL (if equipped) Located below the control lever, this control is used to mute the sound without having to operate the car radio. Press and release the control to mute the sound. Press once again on the control and release, the sound is restored.

NOTE: With the engine stopped, if the sound is muted, it will still be active when the engine is restarted.

8. See "Heating and ventilation or air conditioning controls".

4-7

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES

9

10

CT06K0024

10 9. EMERGENCY SHUT DOWN SWITCH This control enables the engine to be shut down in 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 and the message "ENGINE STOP" is displayed, 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.

IMPORTANT: 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.

4-8

10. QUICK COUPLER LOCKING AND UNLOCKING CONTROL SWITCH (if equipped) See "Quick coupler locking and unlocking control switch".

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES RH CONSOLE

1

3

2

3

4

CT06K022

11 1. SYSTEMS DISPLAY AND FUNCTION CONTROL PANEL See "Systems display and function control panel".

2. OPTION CONTROL (if equipped) These controls are used to control optional accessories such as hydraulic hammer, grab, shears, etc.

See "Auxiliary hydraulic systems" in section 5.

3. STORAGE TRAY 4. AUXILIARY 12 VOLTS SOCKET (optional) This socket is used to power electrical equipment of 12 volts.

4-9

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES SYSTEMS DISPLAY AND FUNCTION CONTROL PANEL 2

1

A H SP !4567

n/min

TRIP

2

ODO

12345.6

1/10H

AUTO

TRIP

n n/min

C

H

C

H

E

F

3 CT06K026

!

WARNING

!

The display panel indicates the machine’s condition and alerts the operator quickly of any abnormalities by means of lamps indicators or buzzers. It is not to be used for determining the time for maintenance operations. The display panel can be damaged by water. Take care that it doesn't get wet during rainy weather or when washing the machine.

NOTE: Wipe the display panel with a soft, dry cloth.

Do not use solvents.

1. FUNCTION AND MESSAGE DISPLAY SCREEN See "Function and message display screen".

2. HORN VOLUME CONTROL Pressing this key toggles the horn alternately between normal volume and reduced volume. Pressing this key is accompanied by a short "beep".

In reduced volume, the green indicator lamp is on, in normal volume the indicator lamp is off.

NOTE: When the engine is restarted, the volume selected before shutting down the engine remains unchanged.

4-10

12 3. TRAVEL SPEED SELECTOR This key is used to change from low speed (I) to high speed (II).

In high speed (II) the red indicator lamps is on, in low speed (I) the indicator lamp is off.

!

WARNING

!

All changes in travel speed should be made while the machine is stationary, otherwise the direction of travel can be changed.

Low speed (I) CX160B (0 to 2.8 km/h) CX180B (0 to 2.3 km/h), select this speed to travel on slopes, rough ground or soft terrain.

High speed (II) CX160B (0 to 5.4 km/h) CX180B (0 to 4.0 km/h), select this speed to travel on hard, flat ground in good terrain conditions.

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

NOTE: When the hydraulic system is overloaded and the machine is in 2nd speed, the machine automatically changes down to 1st speed. The system automatically returns to 2nd speed as soon as the hydraulic system is no longer overloaded.

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES

6

n/min

A H SP !4567

8

TRIP

2

ODO

12345.6

1/10H

AUTO

TRIP

n n/min

C

H

C

H

E

F

7

4

5

9

CT06K026

13 4. AUTOMATIC ENGINE IDLE SPEED SELECTOR Pressing this key toggles alternately between normal idle (switch on the RH control lever) and automatic idle. Pressing this key is accompanied by an audible "beep".

In automatic idle the green indicator lamp is on, in normal idle the indicator lamp is off.

In this position, if no further operations are carried out, the engine will go into idle speed after 5 seconds. (It is possible to increase this lapse of time.

Consult your CASE Dealer). If any controls are then used (control levers, pedals) the engine will revert to its original speed.

NOTE: When the engine is restarted, the automatic idle will still be active if it has been selected before shutting down the engine.

5. WORKING LIGHTS SWITCH This switch switches the working lights on or off. Press the switch for the indicator lamp and the working lights to come on. Press the switch once more to turn them off.

6. WINDSHIELD WIPER SWITCH This switch has three positions: "Off", "Intermittent", "Continuous". Press the switch for intermittent operation of the windshield wiper, the lamp (I) comes on.

Press the switch again to obtain continuous operation of the windshield wiper, the lamp (II) comes on. Press the switch once more to stop the wipers.

7. WINDSHIELD WASHER SWITCH Press and hold the switch for the windshield washer and the windshield wiper to function, release the switch to stop this operation.

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

8. HOURMETER The hourmeter displays engine operation hours and tenths of an hour (6 minutes) and enables maintenance intervals to be calculated. See section 6.

NOTE: The hourmeter can be read even when the engine is switched off.

9. "TRIP" CONTROL (partial hourmeter) This control is used to calculate a specific number of operating hours. Press the control for the hourmeter to read zero and for the "TRIP" message to be displayed.

Then release the control. After approximately one minute the message "TRIP" disappears and the normal hourmeter reading is restored. To consult the specific number of hours displayed, press the control and release it immediately. To cancel the specific hour number display, press the control for about 2 seconds and the specific number of hours reading will return to zero.

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

4-11

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES FUNCTION AND MESSAGE DISPLAY SCREEN 7

n/min

1

C

4

5

6

A H SP !4567

H

C

H

8

2

E

F

3 CT06K027

2 14

1. ENGINE COOLANT TEMPERATURE INDICATOR The degree of temperature is defined by the increase or the decrease in the number of lighted segments.

Zone "C" indicates that the engine coolant temperature is low. If the luminous bars reach zone "H", 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 The degree of temperature is defined by the increase or the decrease in the number of lighted segments.

Zone "C" indicates that the hydraulic fluid temperature is low. If the luminous bars reach zone "H", 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 segments. Zone "F" shows that the fuel tank is full. If the luminous bars reach zone "E", the audible alarm device sounds and the message "LOW FUEL" is displayed (see "Message display").

Use suitable fuel, see "Fluids and lubricants" in section 7.

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

4-12

4. 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".

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

6. ANTI-THEFT PROTECTION INDICATOR This icon is displayed when anti-theft protection is activated. See "Anti-theft protection" in section 5.

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES 7. OPERATING ICONS

8. ACCESSORIES ICONS (if equipped)

Engine idling: This icon shows that the engine idle speed selector has been operated and that the engine is running at idle speed. See item 3 under "Right-hand control arm".

3 Hydraulic breaker 3

Demolition grab

Pressure increase: This icon shows that maximum power has been selected automatically for the attachment.

Automatic heating: This icon shows that engine temperature is automatically rising to working temperature.

It disappears once the engine has reached operating temperature or when the throttle control button or a control lever is operated. See item 2 under "Right-hand control arm".

Engine preheat: This icon shows that it is necessary to warm up the engine. When the engine has reached its working temperature, the icon will disappear.

MESSAGE DISPLAY This part of the screen displays information symbols and messages which will vary depending on the use to which the machine is put. Some of these messages are accompanied by an audible warning. The symbols and messages are listed below along with their explanations.

A H SP

LOW COOLANT

IMPORTANT: When one of these messages is displayed, perform the maintenance operations described in the message.

IMPORTANT: If a message persists after servicing.

Consult your CASE dealer.

CT06K028

NOTE: It is possible to change the language configuration for the messages displayed. Consult your CASE Dealer.

15

SERVICE DUE This message shows that the 500 hours service is due. The message will appear for a minute upon starting the engine. See section 6.

LOW COOLANT This message shows that the coolant level is low. The audible alarm device will sound.

Shut down the engine, remove the starter switch key, allow the system to cool down and then check the coolant level in the expansion reservoir and the radiator. See "Cooling system" in section 7.

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. Use suitable fuel, see "Fluids and lubricants" in section 7.

4-13

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES LOW OIL PRESS. This message shows that the engine oil level is low. The audible alarm device will sound. Shut down the engine, remove the starter switch key and check the level. See "Engine" in section 7.

IMPORTANT: When this is message is displayed, if no action is taken quickly, as described above, the engine will stop automatically.

OVER HEAT This message shows that the temperature of the engine coolant or the hydraulic fluid is too high. The audible alarm device will sound.

Reduce engine speed. If the temperature does not drop, shut down the engine, remove the starter switch key and find the cause of the problem.

IMPORTANT: When this is message is displayed, if no action is taken quickly, as described above, the engine will stop automatically.

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

ELEC. PROBLEM This message shows that there is a fault in the electrical system. The audible alarm device will sound. Shut down the engine, remove the starter switch key and find the cause of the problem, or see your CASE Dealer. See section 9.

AIR FILTER This message shows that service is necessary on the air filter elements. The audible alarm device will sound. See "Air filter" in section 7.

CHECK ENGINE This message shows a problem with the electrical system of the engine (short-circuit or cut-off). The audible alarm device will sound.

Shut down the engine, remove the starter key switch and check the electrical system. See your CASE Dealer.

4-14

BOOST TEMP. HIGH This message shows that the turbocharging air temperature directed on the engine is abnormally high. The audible alarm device will sound. The engine automatically changes to idle mode as a precaution. Shut-down the machine, let the engine run at idle speed and wait till the message disappears.

If the turbocharging air temperature continues to rise during the message display, the engine is automatically cut-off. Consult your CASE Dealer.

CHECK HYD. OIL FILTER This message shows that it is necessary to replace the return hydraulic filter. The audible alarm device will sound. Stop the engine and remove the starter switch key. See "Hydraulic system" in section 7.

SECURITY ON This message shows that the anti-theft protection is activated. The audible alarm device will sound. It is necessary to enter the access code before starting the engine. See "Antitheft protection" in section 5.

ENGINE STOP This message shows that the emergency shut-down switch is activated. The audible alarm device will sound. It must be deactivated to restart the engine. See "Left-hand control arm" (item 9).

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES HEATING AND VENTILATION OR AIR CONDITIONING CONTROLS

6

9

R/F

3 A/C

AUTO

7 MODE

AUTO

2

TEMP

ON

DEF

8

OFF

1

4

5

CS06K016

16 1.

ON/OFF

6.

Air recycling

2.

Automatic

7.

Air flow direction

3.

Air conditioning

8.

Windshield defroster

4.

Ventilation

9.

Display screen

5.

Temperature

On/Off This push-button (1) is for turning the system on or off.

NOTE: When the system is turned on it will operate at the same setting as the one selected previously.

A/C

AUTO

AUTO TEMP

ON OFF

1 CS06K016

17

4-15

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES Ventilation

9

These push buttons (4) enable 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 segments on the display screen (9) will increase or decrease depending on the flow selected.

A/C

AUTO

AUTO TEMP

ON OFF

4 CS06K016

18

Temperature 9

These push buttons (5) allow the temperature to be raised or lowered within an 18 to 32°C 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).

AUTO A TEMP

NOTE: The temperature reading can be displayed in degrees Celsius or degrees Fahrenheit. To select the scale required, press the two push buttons (5) simultaneously for five to ten seconds. The degrees Fahrenheit temperature will be followed by an "F".

O

5

CS06K016

19 Air recycling This button (6) allows for two different types of air circulation to be selected. Fresh air from outside or recycled air from inside. The type of circulation will be changed each time the button is pressed. Indication of the type of flow direction selected will appear on the display screen (9).

(A) Internal air circulated (B) External air enters

9

6 A R/F

B

AUTO

MODE TEMP

DEF

CS06K017

20

4-16

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES Air flow direction This button (7) allows four different types of air flow direction to be selected.

7

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).

R/F

9 AUTO

MODE TEMP

DEF

CS06K016

21 (A) Upper front distribution.

(B) Upper rear distribution.

(C) High force upper distribution and low force rear distribution.

(D) Lower rear distribution (feet) and windshield.

A

B

C

D

CD00E050B

22

Windshield defroster This button (8) allows the windshield to be defrosted.

Press the button to defrost the windshield. The display screen will show that the defroster is working (9). To turn the defroster off, press the button again and the indication on the display screen will disappear.

R/F

AUTO

MODE TEMP

NOTE: When this button is used, the control (7) is deactivated.

DEF

9 8 CS06K016

23

4-17

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES Air conditioning IMPORTANT: 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.

The air conditioning can be used in two different ways: manual or automatic air conditioning.

Manual

6

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).

9

3

AUTO E

A TEMP

O

7

4

5

CS06K016

24 Automatic

9

This button (2) is used for automatic adjustment of the volume, the direction of flow and starting or stopping of the air conditioning. "AUTO" will appear on the display screen (9). In automatic mode, the only possible manual adjustment is to the temperature (5).

2

A/C

AUTO

AUTO

If a control other than the temperature control is operated, the automatic mode will be cancelled and "AUTO" will disappear from the display (9). To stop the system, press buttons (1) or (2).

TEMP

ON OFF

5

1

CS06K016

25 To obtain hot or cold air quickly:

2

Cold air: Quit the automatic mode by pressing button (2) then press button (5) down to the minimum temperature of 18°C. Ventilation will be at maximum and cold air flow will come from the front.

A/C

AUTO

Hot air: Quit the automatic mode by pressing button (2) then press button (5A) up to the maximum temperature of 32°C. Ventilation will be at maximum and the flow of hot air will come from the rear at foot level.

AUTO TEMP

ON OFF

5

5A

CS06K016

26

4-18

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES FUNCTION CANCELLATION LEVER AND SAFETY BAR The safety bar (1) is designed to prevent the operator from leaving the operator’s compartment without first having retracted the safety bar into the LH 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 central position, the safety bar (1) is in inward position in the control arm and the attachment, travel and swing functions cannot be operated.

IMPORTANT: The engine must be started with the safety bar retracted. If the safety bar is extended, it is not possible to start the engine.

2

1

CT06K029

27

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

!

WARNING

2

!

Before leaving the operator’s compartment, it is mandatory for the lever (2) to be in the central position and the safety bar (1) to be in inward position.

NOTE: It is also possible to cancel all controls by completely raising the left-hand control arm. Pull the handle (2) backward.

1 CT06K030

28

4-19

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES DIPPER AND UPPERSTRUCTURE SWING LEFT-HAND CONTROL LEVER 3

The speed of movement of the dipper or the upperstructure swing depends on the control lever tilt angle.

In the intermediate position two movements can be obtained simultaneously.

IMPORTANT: When the upperstructure swing control is released, the upperstructure may continue to rotate due to the force of inertia. In this event, make allowance for the extra movement by releasing the control slightly earlier.

1

2

4

CT06K031

29 1.

2.

3.

4.

The dipper extends.

The dipper retracts.

The upperstructure turns to the left.

The upperstructure turns to the right.

4

3

2

1

CS98N547A

30

BOOM AND BUCKET RIGHT-HAND CONTROL LEVER

6

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

8 7

5 CT06K032

31 5.

6.

7.

8.

The boom lowers.

The boom raises.

The bucket retracts (filling).

The bucket extends (dumping).

6

NOTE: The movements of the machine are shown in the "Control functions" decal. See "Decals" in section 3.

5

7

8 CS98N547A

32 4-20

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES TRAVEL CONTROL LEVERS AND PEDALS To move the machine, see "Machine travel" in section 5.

NOTE: Travel speed either forwards or in reverse depends on the position of the travel speed selector.

See "Control console and functions display panel" (item 3).

NOTE: The movements of the machine are shown in the "Control functions" decal. See "Decals" in section 3.

CT06K033

33

OPTION PEDALS (if equipped) These pedals are used for optional accessories such as hydraulic hammer, if equipped, etc. See "Hydraulic hammer or high flow hydraulic circuits" in section 5.

IMPORTANT: Consult your CASE Dealer before mounting optional tools.

CT06K033

34

ARTICULATED BOOM ADJUSTMENT PEDAL (CX160B) (if equipped) This pedal is used to adjust the articulated boom.

The use of this pedal is coupled with the control on the right-hand control arm, see "Offset-backhoe boom or high flow control".

Press the front of the pedal, the boom opens.

Press the rear of the pedal, the boom closes.

!

WARNING

!

CT07B002

In this attachment configuration, the tool can hit the cab.

35

4-21

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES OFFSET-BACKHOE BOOM (if equipped) OR HIGH FLOW HYDRAULIC CIRCUIT CONTROL PEDAL

1

This pedal is used to control the offset-backhoe boom movement or the high flow hydraulic circuit.

The use of this pedal is coupled with the control on the right-hand control arm, see "Offset-backhoe boom or high flow control".

1.

2.

Operation of the high flow or movement of the offset-backhoe boom to the right.

Movement of the offset-backhoe boom to the left.

2 CT07B002

36

LOW FLOW HYDRAULIC CIRCUIT CONTROL PEDAL (if equipped)

1

This pedal is used to direct the clamshell.

1.

2.

The clamshell turns to the right.

The clamshell turns to the left.

!

WARNING

!

The pedals must mandatorily be locked when not used. See "Adjustment and locking the option pedals".

2 CT07B002

IMPORTANT: Consult your CASE Dealer before mounting optional tools.

4-22

37

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES ADJUSTMENT AND LOCKING THE OPTION PEDALS (if equipped) The adjustment of option pedals is adapted for use with the accessory installed on the attachment.

Accessory using two pedal flows can be operated in two directions, the locking pin (1) is removed.

1

CT06K070

38 Accessory using a single flow can be operated in only one direction, the locking pin (1) is engaged.

1

CT06K071

39 Accessory removed, the pedals must be locked, the locking pin (1) is engaged in the locking hole.

!

WARNING

!

Shut-down the engine before any adjustment of option pedals.

1

CT06K072

40

4-23

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES FOOTREST

CT06M005

41

CAB LIGHT The light is located on the left-hand cab upright and is controlled by a three position switch set in the lamp base.

Positions: "ON" (continuous operation), "OFF" (shutdown) and intermediate position goes off 30 seconds after closing the door.

IMPORTANT: Make sure that the lights are switched off after use, otherwise the batteries may become discharged.

NOTE: To replace bulbs, see "Replacing a bulb" in section 9.

CT06K034

42

COAT HANGER HOOK This hook is on the rear right-hand cab upright.

IMPORTANT: Take care not to obscure the view by clothes that are too bulky.

CT06K035

43

4-24

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES FUSE BOX To access the fuses, open the panel located behind the operator’s seat.

CT06K036

44 Remove the cover of the fuse box. To replace a fuse, see "Fuses" in section 9.

CT06K037

45

4-25

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES QUICK COUPLER LOCKING AND UNLOCKING CONTROL SWITCH (optional) This switch is located on the left-hand control arm.

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

NOTE: For safety reasons, the switch cannot be operated by simply pressing the top.

1

To lock, press the bottom of the switch. In this position, the audible alarm device will cease to function.

NOTE: When locking, it is not necessary to operate the locking pin (1).

IMPORTANT: Each time you change a tool, be sure to place the switch in locked position.

CT06M006

46

See "Quick tool installation and removal" in section 5.

ROOF CURTAIN The curtain can be opened by sliding the curtain towards the rear using the handles. Closing is done by sliding the curtain to the front.

CT06K038

47

ROOF HATCH Open the roof curtain. To open the roof hatch, operate the handle and push the handle. To close the roof hatch, pull the handle until engagement.

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

CT06K039

48

4-26

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES CAB DOOR SLIDING WINDOWS When the locks are released, the windows can be opened and closed to the left or right as required.

CT06K044

49

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

CT06K051

50

MAGAZINE RACK Located on the right-hand side, behind the operator’s seat.

CT06K040

51

REFRIGERATED COMPARTMENT Located on the right-hand side, behind the operator’s seat. This compartment, associated with the air conditioning system, is designed to store different cold or hot products, drinks, etc.

CT06K042

52 4-27

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES STORAGE COMPARTMENT Located on the left-hand side, behind the operator’s seat.

CT06K041

53 Located behind the operator’s seat.

These compartments are used to store various objects.

CT06K040

54

CUP HOLDER Located on the front right-hand side of the operator’s seat, this location is designed to hold a beverage container.

CT06K043

55

4-28

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES OPERATOR'S SEAT

8

9

7

7 3 5

4 1

2 6

CT06M007A

56 1.

2.

3.

4.

5.

Combined height and weight adjustment Weight adjustment indicator Fore/aft adjustment Seat back angle adjustment Lumbar support adjustment

6.

7.

8.

9.

Seat and control arm assembly fore and aft adjustment Armrest angle adjustment Headrest adjustment Seat belt

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.

NOTE: The adjustment of the seat can only be carried out when the operator is seated in the seat and the engine is shut down.

4-29

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES COMBINED HEIGHT AND WEIGHT ADJUSTMENT Turn the control (1) to decrease or increase the rigidity of the suspension. The indicator (2) must be green when the operator is sitting on the seat.

1

2

CT06K046B

57 FORE/AFT ADJUSTMENT Hold the control (3) in the raised position, slide the seat to the required position and then release the control.

3

CT06K046A

58 SEAT BACK ANGLE ADJUSTMENT To adjust the seat back angle, hold the lever (4) in the raised position. Move with the seat-back to the desired position and then release the lever.

!

WARNING

!

Before tilting the seat back it is essential that the armrests are the in raised position to prevent them from interfering with the control levers.

4 CT06K046B

59 LUMBAR SUPPORT ADJUSTMENT 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.

5

CT06K046A

60 4-30

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES SEAT AND CONTROL ARM ASSEMBLY FORE AND AFT ADJUSTMENT Pull the control (6) upwards, and slide the seat and control arm assembly to the desired position, then release the control.

6

CT06M008A

61 ARMREST ANGLE ADJUSTMENT Raise the armrest and adjust to the desired angle using the knob (7), then lower the armrest.

7

CT06K047

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

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

8

CT06K050

63

4-31

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES SEAT BELT Sit comfortably in the operator’s seat, pull out a long section of belt and engage it in the fastening system (9).

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

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

9

!

WARNING

!

Always fasten your safety belt before starting the engine. The safety belt will protect you effectively if you fasten it correctly and wear it at all times. The safety belt should not be too loose. It should not be twisted or caught in the operator’s seat.

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

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

4-32

CT06K048

64

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES WINDSHIELD

!

WARNING

!

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

OPENING 1.

Fold the sunshield (1) back against the windshield and operate the lever (2). Hold the lower and upper handles (3) and carefully raise the windshield.

3

2 1 CT06K051

65 2.

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

CT06K052

66 CLOSING 1.

Use the lever (2) to release the windshield.

2.

Hold both handles (3) and carefully lower the windshield. Make sure the window is completely down.

3.

3

Make sure the top of the windshield is correctly latched.

2 CT06K052

67

4-33

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES LOWER FRONT WINDOW The lower front window may only be removed when the windshield is open.

1.

Remove the window from its housing by sliding it upwards.

CT06K053

68 2.

Place the window in the storage position provided to the left of the operator's seat and then engage it correctly.

CD00E022

69

REAR WINDOW (EMERGENCY EXIT)

!

WARNING

!

2

Remove the rear window only in case of absolute necessity resulting from an emergency.

Do not place any object in front of the window, which may constitute an obstacle in case of evacuation.

Pull on the ring (1), release the seal (2) completely from the frame of the rear window then push it firmly so that it is projected outwards.

To install the window, consult your CASE Dealer.

4-34

1

CT06K054

70

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES FUEL TANK The fuel tank capacity is 300 litres.

Use suitable fuel, see "Fluids and lubricants" in section 7.

IMPORTANT: Do not put a moisture elimination product (water draining agent) in the fuel tank. (It may damage the engine).

NOTE: Clean around the fuel cap before refuelling and do not remove the filter located in the filler orifice. See "Fuel tank filter" in section 8.

NOTE: In cold weather, use fuel corresponding to the ambient temperature. See "Fluids and lubricants" in section 7.

CT07A060

71

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

!

WARNING

!

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

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

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

The fuel tank is equipped with a max level visual gauge.

CT07A061

72

4-35

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES REAR VIEW MIRRORS Before undertaking any travel, make sure the rear view mirrors are clean and properly adjusted.

CAB

CT06K055

73 UPPERSTRUCTURE

CT06K056

74

FRONT STORAGE BOX This is to the front right of the upperstructure. It is used for storing emergency parts.

The storage box also gives access to the fuel tank filler pump (if equipped) and the upperstructure working light.

To open the box cover, use the pushrod of the cylinder.

The door of the box being fitted with a gas strut, follow through the opening or closing movement.

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

CT07A062

!

WARNING

!

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

4-36

75

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES SIDE DOORS RIGHT-HAND DOOR The right-hand door gives access to certain hydraulic components (pump, filter, etc.) and also to the engine fuel and oil filters.

CT07A063

76 LEFT-HAND DOOR The left-hand door is mainly for obtaining access to the batteries, windshield washer tank, air filter, radiator, oil cooler, etc.

Use the outside handle to open the doors. To hold the doors, open, remove the struts from their storage position and install them in the holes provided. When closing, put the struts back into their storage housing.

!

WARNING

!

Always install the struts when the doors are open.

Use the starter switch key to lock the side doors.

!

WARNING

CT07A064

77

!

Never leave tools or other objects behind the side doors.

!

WARNING

!

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

4-37

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES ENGINE HOOD OPENING Unlock the latch locks then lift the hood to the maximum so that it gets automatically locked with the support strut.

!

WARNING

!

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

CT07A065

78 CLOSING Raise the hood slightly, pull the support strut back then lower the hood and slam it shut.

NOTE: To prevent opening of the hood, lock the front latch lock with the starter switch key.

!

WARNING

!

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

CT07A066

79

LOWER PANELS Located under the upperstructure frame, these panels provide access to certain machine components.

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

!

WARNING

!

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

CT07A067

80

4-38

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES WINDSHIELD WASHER RESERVOIR This reservoir, located in the rear left-hand compartment, is equipped with an electric pump which is operated from the control panel. See item 7 under "Systems display and control panel".

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

Remove the cap to add windshield washing fluid.

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

The reservoir can be lifted out of its support.

CT07A068

81

ROTARY LIGHT CABLE This cable is located behind the right-hand rear cab pillar and can be used for connecting a 24 V rotating beacon (not supplied).

CD01D028

82

4-39

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES LOAD HANDLING EYES When lifting loads, the slings and chains must be attached to the load handling eye on the bucket control rod or the quick coupler (if equipped).

See "Load handling" in section 5.

CT06K064

83 IMPORTANT: The quick coupler eye can be used for handling loads up to 5 tonnes.

IMPORTANT: This attachment point will only carry the load indicated in the load handling limits chart.

See "Load handling limits chart" in section 5.

!

WARNING

!

(If equipped) Never handle a load using anchorage points in front or behind the quick coupler.

CD00H002A

!

WARNING

!

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

!

WARNING

!

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

4-40

84

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES TOWING HOLES The towing holes, located at the front and the rear of the undercarriage, are intended for moving heavy objects of up to 10 tonnes maximum.

!

WARNING

!

This is a delicate manoeuvre which is always carried out at the risk of the user. The manufacturer’s warranty does not apply to any incidents or accidents which may occur during towing.

!

WARNING

!

CD00E069

85

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

Make sure that the slings, chains and accessories are in perfect condition and can bear the load to be moved.

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

CAB PROTECTION (F.O.P.S.) (optional) F.O.P.S.: Falling Objects Protective Structure.

It is essential that the cab protection is used when work takes pace in areas where stones or debris may fall. If the machine was not originally equipped with this protection, see your CASE Dealer for its installation.

CT04D008

86

4-41

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES SAFETY VALVES (optional) SERVICE SPECIFICATIONS Check by your CASE Dealer.......................................................................................................Every 6 months On boom cylinders

CT07A069

87 On dipper cylinder The role of the safety valve is to stop the attachment from dropping due to valve spool leakage in neutral position or in the event of a line or hose accidentally breaking. In the latter event, they also ensure that the attachment may be lowered gently to the ground. See "Load handling" in section 5.

CT06K066

88

OPTIONAL TOOL SUPPLY VALVES (optional) Located on each side of the end of the dipper, these valves are used to ensure oil supply to optional tools, for example, hydraulic breakers, etc. These valves have two positions, open/closed.

CT06K067

89

4-42

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES FUEL TANK FILLING PUMP (if equipped)

!

WARNING

!

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

IMPORTANT: Do not put a moisture elimination product (water draining agent) in the fuel tank. (It may damage the engine).

IMPORTANT: This 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 7.

1.

Park the machine on flat, horizontal 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.

CT07A070

90 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.

1

PDF0361

91

4-43

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES 5.

Remove the fuel tank filler cap.

!

WARNING

!

It is essential that the cap is removed before filling.

This prevents any risk of an accident occurring when the cap is opened after filling.

CT07A071

92 6.

Select the filling method using the selector switch located to the right of the filling pump.

"AUTO" mode, the pump stops filling automatically and the audible alarm sounds when the fuel tank is full.

"MANUAL" mode, monitor the filling by means of the reservoir gauge and stop when necessary.

CT07A072

93 7.

Turn the switch located on the pump to the "ON" position (start). Filling begins.

NOTE: It is possible to stop filling at any time for any reason (empty drum, for example) by turning the switch to the "OFF" position.

8.

When the fuel tank is full, turn the switch and the selector switch to the "OFF" position (stopped). In "AUTO" mode the audible alarm device stops.

9.

Run the pump for a few moments to empty the pipe outside the drum. Clean and replace the inlet pipe in the front storage compartment.

10. Refit the fuel tank filler cap.

11. Place the starter switch key in the "OFF" position.

NOTE: The pump is equipped with a 10 Amp fuse.

4-44

CT07A073

94

SECTION 5

46

OPERATING INSTRUCTIONS BEFORE USING THE MACHINE

!

WARNING

!

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

Before operating this machine, be sure to do the following: 1.

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 section 7 and "Operating the machine in cold weather".

2.

Carry out the daily maintenance operations.

See section 6.

3.

Inspect the machine, look for any signs of possible leakage and check the hoses. Tighten or replace as necessary. See section 8.

4.

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

5.

Check the track assemblies. See "Tracks" in section 8.

6.

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

7.

Clean or replace any decals which are illegible.

See "Decals" in section 3.

8.

Make sure that the engine hood and the side doors are properly closed and latched.

9.

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

12. Make sure nobody is on or under the machine.

The operator must be alone on the machine.

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

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

15. Work out a convenient means of escape from the machine (emergency exit via the windshield, the rear window glass) in the event of the cab door being jammed or the machine turning over. See "Windshield" and "Rear window (emergency exit)" in section 4.

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

10. Remove any obstructions which hinder visibility.

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

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

5-1

SECTION 5 - OPERATING INSTRUCTIONS OPERATING THE MACHINE

!

WARNING

!

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

When operating the machine, be sure to do the following: 1.

When starting the engine, be sure to use the correct procedure for the prevailing weather conditions. See "Starting the engine".

2.

Regularly consult the hourmeter to ensure that all servicing operations are carried out punctually. See section 6.

3.

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

4.

Take note of the locations of pipes/cables before starting work.

5.

Do not work near overhead high-voltage electric lines without checking beforehand that all necessary measures have been taken to respect the minimum distances: Less than 57 000 volts: 3 metres More than 57 000 volts: 5 metres

6.

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

7.

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

8.

Modify your driving to suit the type of work and working conditions. See "Machine operation".

9.

Do not allow anyone within the machine's operating radius. Stop all operations until everyone has moved away.

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

5-2

11. Operate all controls gradually to ensure smooth machine operation.

12. See "Operating in water" if the machine will be standing in water during use.

13. See "Transporting the machine" when driving the machine onto a trailer.

14. See "Handling the machine" when it is necessary to lift the machine.

15. See "Towing the machine" when it is necessary to tow the machine.

16. In some configurations, the working range of the attachment allows the tool to interfere with the machine. Always maintain a safe minimum distance between the tool and the machine.

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

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

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

20. In the event of an operation problem or failure, move the machine to a safe place, lower the attachment to the ground, stop the engine, remove the starter switch key. Locate the problem, report it if necessary and take the necessary steps to warn others not to attempt to operate the machine.

21. Do not stop the engine without taking prevailing weather conditions into consideration. See "Stopping the engine".

22. See "Parking the machine" when you have to park the machine.

23. 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".

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

SECTION 5 - OPERATING INSTRUCTIONS RUN-IN PERIOD Your machine will last longer and will give better and more economical performance if you pay particular attention to the engine during the first twenty hours of operation.

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

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

Check all instruments frequently.

Check the oil levels and coolant solution level frequently.

During the run-in period, the following checks and servicing operations should be carried out in addition to those specified in the service schedule: After the first 50 hours Check the pad screws are tightened to the correct torque. See "Tracks" in section 8.

Check all nuts and screws are tightened to the correct torque. See "Hardware torque inspection" in section 8.

(If equipped) Check the cab protective structure.

See "Cab protection (F.O.P.S.)" in section 8.

After the first 250 hours Replace the pilot circuit filter and the return filter.

See "Hydraulic system" in section 7.

Change the oil in the travel reduction gears. See "Travel reduction gears" in section 7.

Change the oil in the swing reduction gear. See "Swing reduction gear" in section 7.

5-3

SECTION 5 - OPERATING INSTRUCTIONS ANTI-THEFT DEVICE To prevent the machine from being stolen it is possible to use the anti-theft device, which makes it necessary for a special code to be entered before the machine can be operated.

To configure the anti-theft device, consult your CASE Dealer.

The effects of the device are: - The engine runs at idle speed.

- The audible alarm device will sound.

- The engine stops if the machine is handled.

Once the machine has been configured, a special access code has to be recorded which must be entered whenever you start the engine.

IMPORTANT: Once the code has been recorded, do not forget it, as it can not be changed without consulting your CASE Dealer.

Recording the code 1.

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

2.

The message "PASSWORD" and four boxes will appear on the display screen.

?

?

?

?

CT06K075

1 3. To register the code use the following keys: - Windshield washer key (1) to move the cursor to the left.

- Working light key (2) to move the cursor to the right.

- Windshield wiper key (3) to increment the digits (0, 1, 2, 3...).

- Windshield wiper key (4) to decrement the digits (...3, 2, 1, 0).

1

3

TRIP

2

123 AUTO

T

n n/min

F

5

4

2

CT06K026

2

5-4

SECTION 5 - OPERATING INSTRUCTIONS 4.

Once all four digits have been entered, press button (5) for the code to be entered in the system.

The screen returns to its normal display.

IMPORTANT: Remember to keep careful note of the code number, because if you forget it, it will not be possible to record a new one without consulting your CASE Dealer.

Using the anti-theft device The anti-theft device has to be activated when you are shutting down the engine. Turn the starter switch from "ON" to "OFF", "ON" to "OFF" for about 2 seconds at a time until the audible alarm device sounds. The icon of the anti-theft device is displayed on the screen, the anti-theft device is activated, now the access code will have to be entered when starting the engine.

A H SP

You are not obliged to activate the anti-theft device.

In that case all you have to do is to turn the starter switch key to the "OFF" position when shutting down the engine. In that configuration, it will not be necessary to enter the code when starting the engine.

C

H

C

H

E

F

CT06K076

Entering the access code

3

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

1.

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

2.

The message "PASSWORD" and four boxes will appear on the display screen.

3.

Enter the code in the same manner as during registration. Once all four digits have been entered, validate with the button (5).

TRIP

2

123 AUTO

T

n n/min

F

5 CT06K026

4

5-5

SECTION 5 - OPERATING INSTRUCTIONS If the access code has been entered correctly, the icon of the anti-theft device will disappear from the screen and it will be possible to start the engine.

If the code is wrong or if the code is different from the one registered, the message "ERROR" is displayed, the operation has to be restarted.

Place the starter switch key in the "OFF" position and repeat Steps 1 to 3.

NOTE: If the anti-theft device was activated the last time the engine was turned off, it will still be possible to start the machine without the access code, or with the wrong code, but the engine will run at idle speed, and will stop if the machine is handled.

5-6

A H SP

C

H

C

H

E

F

CT06K077

5

SECTION 5 - OPERATING INSTRUCTIONS STARTING THE ENGINE NOTE: If the machine has been out of use for some time, see "Starting up after storage" in section 10.

NOTE: See "Connecting booster batteries" in section 9, if you have to start the engine using booster batteries.

1.

Take up position correctly in the operator's seat with the seat belt correctly fastened. See "Operator's seat" in section 4.

2.

Make sure the function cancellation lever is in the central position (safety bar in inward position).

CT06K029

6 3.

Make sure the engine throttle button (1) is in low idle position. In cold weather, leave it in half-way position.

4.

Turn the starter switch key (2) to the "ON" position.

5.

If necessary, enter the anti-theft code. See "Antitheft device".

2 1

1

2

CT06M021

7 In cold weather, the "Engine preheat" icon appears on the systems display panel. See "Control and function display console" in section 4.

6.

A H SP

When the icon disappears, turn the key (2) to the "START" position. Release the key as soon as the engine starts to turn. If the engine stops, wait about a minute and perform the operation again.

IMPORTANT: 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.

CT06K078A

8

5-7

SECTION 5 - OPERATING INSTRUCTIONS 7.

Run the engine until the "Automatic heating" icon disappears from the systems display panel. See "Control and function display console" in section 4.

8.

Sound the horn button on the left-hand control lever to give warning of your intention to start the machine.

CT06K080

9 9.

Push the function cancellation lever forward (safety bar in outward position).

IMPORTANT: Check the systems display and console frequently whilst the engine is running. See "Engine operation".

IMPORTANT: This machine is equipped with a new type of engine incorporating a high-pressure fuel injection system which reduces the emission to the environment and respects the regulations applicable to level III engine emissions.

Starting this engine takes about 1 second before stabilisation.

IMPORTANT: If the engine does not start at the first attempt, operate the starter motor for 10 seconds then wait for 1 to 2 minutes before retrying.

When cold, the engine is at times difficult to start.

But in all cases, do not operate the starter motor for more than 10 seconds.

5-8

CT06K030

10

SECTION 5 - OPERATING INSTRUCTIONS BRINGING THE MACHINE UP TO OPERATING TEMPERATURE IMPORTANT: Normal operating temperature of the hydraulic fluid is between 50°C and 80°C, in the middle of the temperature indicator. If the machine is used with the hydraulic fluid at a temperature below 20°C, damage can be caused.

After starting the engine and before using the machine, allow the hydraulic fluid to reach a temperature of 20°C, as indicated by the appearance of the first two segments on the hydraulic fluid temperature indicator. See "Function and message display screen" (Item 2) in section 4.

ENGINE AUTOMATIC WARM-UP

HYDRAULIC FLUID WARM-UP

Once the engine has started, the warming-up process begins automatically. At first, engine speed is held at a pre-determined, low level. As the temperature increases, engine speed increases in proportion. It is possible to interrupt the warming-up process at any time, simply by manually changing engine speed or by operating one of the control levers. Warming-up takes approximately 5 to 10 minutes.

Turn the engine throttle button to half-open position.

Push the function cancellation lever forward (safety bar in outward position). Operate the bucket control slowly until the bucket is completely closed. Operate the dipper retracting control slowly until the dipper is completely retracted and hold the control in this position for 30 seconds. During this time the temperature of the hydraulic fluid will increase.

MANUAL ENGINE WARM-UP

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

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

Continue the dipper extending and retracting procedure until the temperature rises (first two segments of the temperature indicator), see "Function and message display screen" (item 2) in section 4.

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

5-9

SECTION 5 - OPERATING INSTRUCTIONS ENGINE OPERATION

!

WARNING

!

There is high pressure fuel in the feed pipe when the engine is running and immediately after it has been shut down. Wait for 2 minutes after engine shut down before you do any maintenance or inspections to allow the pressure to drop in the pipe.

!

WARNING

!

High voltage is charged to the controller and/or the injector when the engine is running and immediately after it has been shut down.

Do not touch the controller or the injector.

If it is necessary to touch them for maintenance purposes, consult your CASE Dealer.

When the engine has started and before beginning work, the following procedure must be observed: - Let the engine idle for about five minutes until it has warmed up.

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

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

- There is no abnormal noise or vibration.

- There are no oil, fuel or water leaks.

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

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

Check the systems display and console regularly.

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

5-10

SECTION 5 - OPERATING INSTRUCTIONS STOPPING THE ENGINE 1.

Lower the attachment until it is resting on the ground.

2.

Turn the engine throttle button (1) to low idle position and let the engine run for a minute or so.

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

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

3.

2 1

Turn the starter switch key (2) to the "OFF" position.

NOTE: To activate the anti-theft device when stopping the engine, see "Anti-theft device".

CT06M012

11

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

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

The message "ENGINE STOP" appears on the systems display panel.

CT06K024

12

5-11

SECTION 5 - OPERATING INSTRUCTIONS OPERATING THE MACHINE IN COLD WEATHER Follow the recommendations shown below: BATTERIES They should be fully charged.

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, use fuel which is rated for the ambient temperature or add an appropriate antifreeze to the fuel. See "Fluids and lubricants" in section 7.

ENGINE OIL It should be of the right viscosity for the ambient temperature. See "Fluids and lubricants" in section 7.

HYDRAULIC FLUID The viscosity must correspond to the ambient temperature conditions. See "Fluids and lubricants" in section 7.

COOLANT SOLUTION It must have specifications corresponding to the ambient temperature. See "Fluids and lubricants" in section 7.

5-12

SECTION 5 - OPERATING INSTRUCTIONS OPERATING THE MACHINE IN HOT WEATHER Follow the recommendations made below: 1.

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

2.

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

3.

Test the radiator cap before hot weather starts.

Replace the cap as required.

4.

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

5.

Check the condition of the fan drive belt.

6.

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

7.

Use lubricants of the correct viscosity. See "Fluids and lubricants" in section 7.

5-13

SECTION 5 - OPERATING INSTRUCTIONS MACHINE OPERATION OPERATING INSTRUCTIONS

!

WARNING

!

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

- 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.

- The following operations are likely to damage the machine. You are therefore advised to avoid them: 1) Excavation using the weight of the machine as a force of impact.

2) Excavation using the machine’s travel force.

- 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.

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

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

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

- When travelling at right angles to the slope, move on to the slope at low speed. Never reduce engine speed when travelling 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.

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

More than 57 000 volts: 5 metres.

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

- Never sweep the ground with the bucket to level rubble.

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

5-14

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

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

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

- Avoid turning the machine on steep slopes.

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

OPERATION 1.

Sit in the operator's seat and adjust it so that all the controls are readily accessible. See "Operator's seat" in section 4. Then fasten your safety belt.

2.

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

3.

Sound the horn.

4.

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

5.

Check all indicator lamps and gauges are operating correctly.

6.

Push the function cancellation lever forward (safety bar in outward position).

7.

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

SECTION 5 - OPERATING INSTRUCTIONS MACHINE TRAVEL

!

WARNING

!

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

IMPORTANT: Before undertaking any travel, raise the attachment.

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

NOTE: The different travel configurations described hereafter are with the travel reduction gears to the rear of the upperstructure.

STRAIGHT LINE TRAVEL (forward travel) Press the two pedals (or push the two levers) forwards at the same time.

CS98M546

13 STRAIGHT LINE TRAVEL (reverse travel) Press the two pedals (or push the two levers) rearwards at the same time.

CS98M547

14

5-15

SECTION 5 - OPERATING INSTRUCTIONS TURNING TO THE LEFT (forward travel) Simply press the right-hand pedal or the right-hand lever forwards.

CS98M548

15 TURNING TO THE RIGHT (forward travel) Simply press the left-hand pedal or the left-hand lever forwards.

CS98M551

16 TURNING TO THE LEFT (reverse travel) Simply press the right-hand pedal or the right-hand lever rearwards.

CS98M549

17 TURNING TO THE RIGHT (reverse travel) Simply press the left-hand pedal or the left-hand lever rearwards.

CS98M550

18 5-16

SECTION 5 - OPERATING INSTRUCTIONS TURNING ON THE SPOT, TO THE RIGHT Press the left-hand pedal or the left-hand lever forwards and at the same time press the right-hand pedal or the right-hand lever rearwards.

CS98M552

19 TURNING ON THE SPOT, TO THE LEFT Press the right-hand pedal or the right-hand lever forwards and at the same time press the left-hand pedal or the left-hand lever rearwards.

IMPORTANT: Turning on the spot cannot be done if high speed travel is selected.

CS98M553

20 GRADUAL TURN ON THE MOVE Press one of the pedals or one of the levers and, at the same time, press the other pedal or the other lever in the same direction, but slightly harder.

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

CS98M545

21

5-17

SECTION 5 - OPERATING INSTRUCTIONS HANDLING THE MACHINE Never perform handling operations without having retracted the attachment beforehand, bucket and dipper cylinders fully extended then place the attachment on the ground. Shutdown the engine and leave the operator’s compartment.

IMPORTANT: Before handling the machine, make sure the slings are in perfect condition and that they are capable of supporting the weight of the machine.

See "Weight" in section 11.

IMPORTANT: It is imperative to use the sling points indicated on the machine decals. See "Decals" in section 3.

CT06K079

22

!

WARNING

!

The machine must be handled very slowly and horizontally.

!

WARNING

!

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

CT06K081

23

5-18

SECTION 5 - OPERATING INSTRUCTIONS LOAD HANDLING

!

WARNING

!

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

When lifting a load (tubes, concrete pipe connections, shoring material, etc.) the machine must be equipped with safety valves, an overload indicator, a load fixing point and a load handling chart corresponding to the type of machine and to its attachment. See "Load handling limits charts".

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

When handling loads, be sure to do the following: - Park the machine on a flat, firm, level surface.

- Fix the load to the load fixing point (load handling eye) located on the quick coupler (optional) (see "Load handling eyes" in section 4) or on the bucket control rod, see "Load handling limits charts". It is forbidden to weld hooks or lugs on the bottom plate of buckets.

- Use slings and chains which are in perfect condition, suitable for lifting the load to be handled and fitted with safety type hooks that will not accidentally open.

- Check that the safety valves function correctly. The pressure setting must be checked every 6 months, in conformance with prevailing regulations and/or the maker's instructions. Consult your CASE Dealer.

- Make sure the load handling chart is in the dust jacket specially provided and that it corresponds to the machine version and the attachment mounted. See "Load handling limits charts".

- Mandatorily place the overload indicator switch in the "ON" position.

- Select the "H" work mode. See "RH control arm" (Item 2) in section 4.

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

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

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

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

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

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

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

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

5-19

SECTION 5 - OPERATING INSTRUCTIONS HANDLING THE LOAD WITH THE QUICK COUPLER (optional) 1.

The load with the quick coupler (according to the model) must be handled with the bucket cylinder rod completely extended.

IMPORTANT: Maintain this position throughout the load handling operation.

CT02J046

24 2.

The handling eye must be able to be seen from the cab throughout the load handling operation.

It is strictly forbidden to use the front or rear fixing points (1) of the quick coupler to handle the load.

NOTE: The quick coupler eye can be used for handling loads up to 5 tonnes.

1

CT02J047

25 NOTE: Load handling on CASE machines is in conformity with standard EN 474-1 and standard EN 474-5 relative to directive 98/37/EC.

5-20

SECTION 5 - OPERATING INSTRUCTIONS LOAD HANDLING LIMITS CHARTS 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.

Loads are in daN (1 daN = 1.02 kg) for a machine with bucket, bucket cylinder rod completely extended and for full upperstructure swing, with a built-in safety margin factor of: - 33% on stability, - 15% on hydraulic limits, taking the connecting rod eye as the load fixing point.

IMPORTANT: The weight of the quick coupler (if equipped) has to be subtracted from the given values. See "Weight" in section 11.

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

CS00E556

26

OPERATING THE MACHINE IN WATER 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.

2.

Only the undercarriage must be below water level. The maximum water level must not be higher than the height of the tracks (A = 0.70 m).

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

3.

A

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

CT06M003

IMPORTANT: Do not operate in a fast flowing stream.

27

5-21

SECTION 5 - OPERATING INSTRUCTIONS OPERATING THE MACHINE ON SLOPING GROUND

!

WARNING

!

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

- During hillside operations, be extra careful.

- Make sure that the low speed travel is selected.

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

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

OPERATING THE BACKHOE BUCKET FILLING Fill the backhoe bucket by manoeuvring the dipper. Keep the bottom of the backhoe bucket parallel to the cut.

The backhoe bucket teeth and blade must cut the ground like the blade of a knife. The depth of dig varies depending on the type of material.

EXCAVATING METHOD

PDH0493M

28

1

2

3

PDH0494M

29 1.

2.

3.

Correct Incorrect. The backhoe bucket will dig in and cause a stall Incorrect. The backhoe bucket is pushed upwards. This will also increase the cycle time

5-22

SECTION 5 - OPERATING INSTRUCTIONS QUICK COUPLER INSTALLATION (optional)

!

WARNING

!

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

Install the quick coupler on the dipper and on the connecting rod using the CASE linkage pins (1) supplied and then make the supply line connections.

IMPORTANT: The quick coupler can be used in conjunction with hydraulic breakers, but is not designed to withstand excessive vibration over long periods of the time. It is therefore recommended to remove the quick coupler, to reduce the risk of premature wear, failures or breakage. If you do decide to use a hydraulic breaker, always orientate the breaker towards the machine and never use it as a lever, as the stress would be borne by the quick coupler cylinder.

1

CT02C204

30

QUICK TOOL INSTALLATION AND REMOVAL (optional) IMPORTANT: This quick coupler 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.). Consult your CASE Dealer.

!

WARNING

!

It is strictly forbidden for anybody to remain in the machine operating area during tool installation and removal operations.

5-23

SECTION 5 - OPERATING INSTRUCTIONS INSTALLATION 1.

Make sure the tool to be installed is laying safely on flat, level ground and that it is fitted with the pins supplied with the quick coupler.

2.

Place the switch (1) in unlocking position. The audible alarm device will sound. See "Quick coupler locking and unlocking switch" in section 4.

1

CT06M006

31 3.

Operate the dipper and bucket controls so that the dipper is practically vertical, sloping slightly towards the cab, to release the safety device.

Extend the bucket cylinder rod completely and maintain the hydraulic pressure so that the latching hook retracts.

CT02C205

32 4.

Operate the dipper control lever so as to bring the quick coupler hook (2) around the tool pin (3).

3

2

CT02C206

33

5-24

SECTION 5 - OPERATING INSTRUCTIONS 5.

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

CT02C207

34 6.

Raise the dipper and operate the bucket control to extend the bucket cylinder rod completely.

CT02C208

35 7.

Place the switch (1) in the locked position. The audible alarm device will cease functioning.

See "Quick coupler locking and unlocking switch" in section 4.

1

CT06M006

36 8.

Maintain the pressure in the bucket cylinder to allow the latching hook to close. Raise the attachment so you can see the bucket pin.

CT02C209

37 5-25

SECTION 5 - OPERATING INSTRUCTIONS 9.

Make sure you can see that the bucket pin is correctly engaged in the latching hook.

IMPORTANT: If it is not possible to make a visual check sitting in the operator's seat, get down from the machine and make sure that the tool is correctly connected with the safety device engaged.

CT02C210

38 10. Operate the bucket control to retract the cylinder rod and allow the safety device to engage.

CT02C211

39 DISASSEMBLY 1.

Operate the dipper and bucket controls so that the dipper is practically vertical, sloping slightly towards the cab, to release the safety device.

Extend the bucket cylinder rod completely and maintain the hydraulic pressure so that the latching hook retracts.

CT02C208

40 2.

Place the switch (1) in unlocking position. The audible alarm device will sound.

See "Quick coupler locking and unlocking switch" in section 4.

1

CT06M006

41 5-26

SECTION 5 - OPERATING INSTRUCTIONS 3.

Operate the bucket control to lay the bucket safely on flat, level ground.

CT02C215

42 4.

Operate the dipper control to unhook the tool.

CT02C216

43

5-27

SECTION 5 - OPERATING INSTRUCTIONS PARKING THE MACHINE 1.

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

2.

Place the upperstructure frame in line with the undercarriage, retract the attachment, dig the bucket into the ground to anchor it.

3.

Turn the engine throttle button to low idle position and let the engine run for approximately one minute.

4.

If necessary, activate the anti-theft device. See "Anti-theft device".

CT06M021

44 5.

Stop the engine, remove the starter switch key.

CT06M022

45 6.

Place the function cancellation lever in the central position (safety bar in inward position).

CT06K029

46

5-28

SECTION 5 - OPERATING INSTRUCTIONS 7.

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

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

!

WARNING

!

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

CT06K017

47

5-29

SECTION 5 - OPERATING INSTRUCTIONS TOWING THE MACHINE Towing is only authorized when the machine has broken down.

First, make sure that it can be towed without risk of further damage.

As far as possible try to carry out repairs on spot or contact your CASE Dealer.

!

WARNING

!

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

!

WARNING

!

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

!

WARNING

!

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.

5-30

SECTION 5 - OPERATING INSTRUCTIONS LOWERING THE ATTACHMENT IN THE EVENT OF A MACHINE FAILURE If the engine breaks down, use the following procedure to lower the attachment: 1.

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

CT06M021

48 2.

Push the function cancellation lever forward (safety bar in outward position).

CT06K030

49 3.

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

CT06K082

50

5-31

SECTION 5 - OPERATING INSTRUCTIONS AUXILIARY HYDRAULIC CIRCUITS Your machine has two types of auxiliary hydraulic circuit. One circuit is for single flow equipment, such as hydraulic breakers. The second type of circuit is designed for two flow use such as demolition grabs, etc.

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

!

WARNING

!

To prevent failure or damage to the tool, make sure that you select the correct circuit configuration and flow rate for the tool.

If the machine is equipped with an articulated boom or offset-backhoe boom, the control must be set to "OFF". To use the articulated boom or move the offsetbackhoe boom, set the control to "ON". See "RH control arm" (Item 9 and 9A) in section 4.

CT06K022A

51

5-32

SECTION 5 - OPERATING INSTRUCTIONS HYDRAULIC BREAKER OR HIGH FLOW HYDRAULIC CIRCUITS (optional) Your machine has two types of auxiliary hydraulic circuit. One circuit is 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 or for use with double flow such as demolition concrete crushers, etc.

Hydraulic breaker or single flow hydraulic circuit configuration 1.

Make sure the necessary tool connections and then, using a hexagonal wrench, open the supply valves.

CT06K067

52 2.

Toggle the switch (1) located on the RH console downwards, corresponding to the hydraulic breaker.

3.

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

NOTE: In normal working position (digging) the switch (2) must be in the "OFF" position.

2 1 CT06K083

53 4.

Every time this switch (1) is pressed, one of the different types of flows recorded for the pump can be selected.

5.

The icon of the accessory associated to each type of flow appears on the screen.

A H SP

1

CT06K086

54

5-33

SECTION 5 - OPERATING INSTRUCTIONS 6.

Unlock the pedal and engage the locking pin.

CT06K071

55 7.

Use the control pedal to operate the hydraulic breaker.

CT06K033

56 8.

During operation the flow is displayed on the screen.

A H SP

1

CT06K084A

57

5-34

SECTION 5 - OPERATING INSTRUCTIONS Double flow concrete crusher configuration 1.

Make sure the necessary tool connections and then, using a hexagonal wrench, open the supply valves.

CT06K067

58 2.

Toggle the switch (1) located on the RH console upwards, corresponding to the demolition grab.

3.

Toggle upwards the switch (2) to the "ON" position corresponding to a double flow hydraulic circuit.

1 2

NOTE: In normal working position (digging) or in hydraulic breaker configuration the switch (2) must be in the "OFF" position.

CT06K083

59 4.

Every time this switch (1) is pressed, one of the different types of flows recorded for the pump can be selected.

A H SP

3

CT06K087

60

5-35

SECTION 5 - OPERATING INSTRUCTIONS 5.

Unlock the pedal.

CT06K070

61 6.

Use the control pedal to operate the concrete crusher.

CT06K033

62 7.

During operation the flow is displayed on the screen.

A H SP

3

386 406

CT06K084

63

5-36

SECTION 5 - OPERATING INSTRUCTIONS AUXILIARY HYDRAULIC CIRCUIT FLOW PATTERNS The values of the flow patterns 1, 2 and 3 shown below correspond to the initial values. They can be identified by the number on the screen.

NOTE: The number of setting patterns is 3 maximum.

Values

1 flow (l/min)

2 flows (l/min)

A

142

284

B

132

274

1

122

264

C

110

252

2

95

237

D

83

225

3

70

212

E

57

199

F

43

185

G

35

177

NOTE: The values A to G are the possible programmable values.

Changing the flow patterns

!

WARNING

!

To prevent failure or damage to the tool, make sure that you select the correct circuit configuration and flow rate for the tool.

1.

Operate the switch (1) located on the RH console to display the flow pattern to be changed.

1 CT06K083

64

5-37

SECTION 5 - OPERATING INSTRUCTIONS 2.

The recorded value can be identified by the number shown on the screen. (e.g.: 1 = value 1 in the table).

3.

Hold the switch (1) pressed for 3 seconds, the changing flow rate screen (2) appears.

A H SP

1

406 2 CT06K084B

65 4.

Operate the windshield wiper switch (1) to show the previous pattern.

Operate the auto idling switch (2) to show the following pattern.

5.

Operate the travel speed switch (3) to record.

1

2

AUTO

n n/min

E

CT06K026

F

3

2 66

5-38

SECTION 5 - OPERATING INSTRUCTIONS TRANSPORTING THE MACHINE IMPORTANT: For transporting the machine without attachment, the counterweight must be removed, contact your CASE Dealer.

REMOVING THE ATTACHMENT FROM THE MACHINE The use of lifting systems is necessary for removal and installation of the machine attachment and counterweight. Consult your CASE Dealer.

!

WARNING

!

First of all, assign a person as supervisor to direct the operation and agree on the safety measures, procedures and suitable hand signals.

!

WARNING

!

The use of lifting systems must be entrusted to qualified personnel. The operators and all the personnel assigned to this operation must be perfectly aware of the procedures to be followed.

Make sure that the devices and lifting cables are in good condition.

!

WARNING

!

WARNING

!

Before removing the attachment from the machine, make sure that the air pressure and hydraulic oil pressure are at zero.

!

WARNING

!

Prevent dust and contamination entering open circuits. Any contamination of circuits can cause malfunction of the machine.

!

Since this operation may be dangerous, you are advised to wear suitable clothing and to respect the relevant safety measures.

5-39

SECTION 5 - OPERATING INSTRUCTIONS

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

ON A TRAILER

!

WARNING

!

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

!

WARNING

!

It is mandatory to remove the counterweight before transporting the machine without the attachment. Consult your CASE Dealer.

Make sure you know the safety rules and regulations before transporting the machine. Make sure both trailer and machine are fitted with the right safety equipment.

LOADING 1.

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

CT02C196

67 2.

Select the automatic engine idle function.

567

2

AUTO

n n/min

H

E

F

CT06K026

68

5-40

SECTION 5 - OPERATING INSTRUCTIONS 3.

Select low travel speed, indicator lamp off.

!4567

2

AUTO

n n/min

H

E

F

CT06K026

69 4.

(Machine with attachment)

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

Raise the attachment and bring it to about twenty centimetres above the bed of the trailer.

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

PDH0248

70 5.

(Machine without attachment)

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

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

CS99B518

71

5-41

SECTION 5 - OPERATING INSTRUCTIONS 6.

(Machine with attachment)

When the machine is completely on the trailer, swing the upperstructure to bring the attachment round to the ramp end.

PDH0250

72 7.

(Machine with attachment)

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

PDH0251

73 7.

(Machine without attachment)

Move the machine right to the front of the trailer, swing the upperstructure.

8.

Stop the engine, remove the starter switch key, place the function cancellation lever in the central position (with the safety bar inward).

9.

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

10. Fold the rear view mirrors inwards.

CS99B519

74 11. Use blocks and chains to fasten the machine and the attachment (if equipped) to the trailer.

PDF0360

75 5-42

SECTION 5 - OPERATING INSTRUCTIONS 12. Measure the distance between the ground and the highest point of the machine. You must know the overall height.

PDH0251

76 UNLOADING 1.

Remove the blocks and fastening chains.

2.

Start the engine.

3.

Push the function cancellation lever forward (safety bar in outward position).

4.

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

5.

Select low travel speed.

6.

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

7.

Turn the rear view mirrors back to their correct position.

8.

(Machine without attachment) Install the dipper and the bucket.

IMPORTANT: When the attachment has been installed, all air must be removed from the hydraulic circuit and the machine must be tested for correct operation. Do not forget to check the oil level.

5-43

SECTION 5 - OPERATING INSTRUCTIONS HANDLING THE HYDRAULIC BREAKER (optional) The lifting equipment must be strong enough to take the weight of the hydraulic breaker. See "Hydraulic breakers" in section 11.

CB 150 model - Attach the slings and chains as shown opposite.

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

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

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

CS99C626

77 CB 200S model NOTE: It is mandatory for the lifting ring (1) to be removed and the ring hole plugged before using the hydraulic breaker.

1

CS99C627

78

HYDRAULIC BREAKER BREAKING PRINCIPLES (optional) To increase the life of the hydraulic breaker, follow carefully the methods of operation as well as the criteria for selection of the tool suitable for the work. There are two main methods of breaking using the hydraulic breaker.

IMPACT BREAKING

BREAKING BY PENETRATION (or cutting)

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

In this form of breaking a moil point or chisel tool is forced inside the material. This method is most effective in soft, layered or plastic, low abrasive material.

The high impact rate of the small breakers makes them ideal for penetrative breaking.

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

5-44

SECTION 5 - OPERATING INSTRUCTIONS CHOICE OF THE TOOLS ON THE HYDRAULIC BREAKER (optional) Selection of standard and special tools to suit each application are available. The correct type of tool must be selected to get the best possible working results and longest life time for the tool. Choosing the best tool type for an application may require some testing. Consult your CASE Dealer.

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

- Concrete.

- Trenching and benching.

ASPHALT SHOVEL - Closed grained frozen or ground asphalt.

COMPACTION PLATE - To compact the ground.

It is important to select a tool that is suited to the hydraulic breaker as well as the application which you are working on. The choice of tool depends on the model of the hydraulic breaker. See "Hydraulic breaker" in section 11.

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

- Concrete.

- Breaking boulders.

SPECIAL CONDITIONS OF USE OF THE HYDRAULIC BREAKER (optional) Use of the hydraulic breaker in conditions that are different from normal crushing and demolition conditions, such as: - tunnelling, - foundry cleaning, - underwater operations, - operations in extremely high or low temperatures, - use of special hydraulic fluids, - hydraulic breaker operations on the machine with special attachment (extra long boom etc.), - other special conditions, may require modification of the accessory, employing of special operational techniques, increase in maintenance or special protective parts.

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

5-45

SECTION 5 - OPERATING INSTRUCTIONS

NOTES

5-46

SECTION 6

8

SERVICING INTERVALS SERVICING INSTRUCTIONS Respect the maintenance intervals by checking the hourmeter every day. Before starting maintenance, park the machine on flat, firm ground, away from any obstacles, with the dipper retracted and the bucket on the ground. Unless otherwise specified, all maintenance operations must be carried out with the engine stopped, and the key removed from the starter switch.

It is preferable to wait for all circuits to cool down before starting work.

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.

!

WARNING

!

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

!

WARNING

!

If the attachment is raised or if the machine moves without an operator, serious injury can result.

Before performing any maintenance, proceed as follows: 1. Park the machine on flat, level ground.

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

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

4. Lock the tracks to prevent any machine movement.

!

WARNING

!

Be sure all the service operations in this section are carried out punctually at the intervals given, in order to ensure optimum performance levels and maximum safety when using the machine.

When carrying out service work on the machine, place a "Do not operate" tag on the instrument panel. Never climb down from the operator's compartment leaving the engine running.

Remove the necessary lower panels during maintenance of certain machine components.

!

WARNING

!

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

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

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

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

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

6-1

SECTION 6 - SERVICING INTERVALS HOURMETER The hourmeter enables service operations to be scheduled. Its hourly indications are the same as those of a clock when the engine is running.

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

TRIP

ODO

TRIP ODO 12345.6

12345.6

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

1/10H

1/10H

AUTO

AUTO

n n/min

n n/min

TRIP TRIP

CT06K026

1

DAILY INSPECTIONS Every day, before starting work, it is necessary to inspect the machine and service certain of its components.

GENERAL REMARKS - Check signs of leaking oil or water.

- Check that all screws and nuts are correctly tightened.

- Wipe off any dust (engine, operator's compartment etc.).

- Check for any signs of damage.

ENGINE - Check the oil level and change the oil if necessary.

- Check the coolant level.

- Check the radiator for signs of clogging or deterioration.

- Check the radiator fan belt tension.

- Check the air filter is clean and not restricted.

- Check the components for signs of leaking oil or water.

- Check the condition of all lines.

UPPERSTRUCTURE - 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 hardware.

- Check the condition of the tracks.

- 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.

- Check the condition of the bucket teeth.

6-2

SECTION 6 - SERVICING INTERVALS AFTER STARTING THE ENGINE - Did the engine start correctly? Are the exhaust fumes normal? Any strange noises?

- Check for abnormal noise on the hydraulic components.

- 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.

IMPORTANT: If the slightest defect is found, repair it immediately before using the machine or see your CASE Dealer.

6-3

SECTION 6 - SERVICING INTERVALS QUICK COUPLER SERVICING INSTRUCTIONS (optional) EVERY DAY AND BEFORE EACH INSTALLATION OF THE QUICK COUPLER Check that the locking bar functions correctly and that it is not fouled by foreign matter.

Check the quick coupler cylinder hoses for free movement.

Check the return spring and its mounting hardware.

Check for any signs of cracks.

!

WARNING

!

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

CT02C242

Modification of the quick coupler without prior authorization can cause serious injury. Do not carry out any modification without authorization. Consult your CASE Dealer.

IMPORTANT: If you use your quick coupler under particularly severe conditions (with a hydraulic breaker or in a corrosive environment, etc.) the servicing and inspection intervals must be reduced.

QUICK COUPLER INCORRECT FUNCTIONING (optional) IMPORTANT: Make sure that the attachment is in full contact with the ground before carrying out the following checks.

If the quick coupler does not work correctly, check the following items: - That no pin is broken, bent or lost.

- That no foreign matter is fouling the safety device.

- The condition of the return spring.

- That the cylinder is not damaged or bent.

- That there are no leaks from hydraulic hoses, etc.

If the problem persists after all these checks, consult your CASE Dealer.

6-4

2

SECTION 6 - SERVICING INTERVALS HYDRAULIC BREAKER SERVICING INSTRUCTIONS (optional) Every 2 hours Grease the tool shank and the tool bushing.

Tighten any loose connections.

Check the impact efficiency and evenness of operation.

Every 10 hours or once a week Remove the tool retaining pins and check their condition. Grind burrs away if necessary. See "Replacing a tool on a hydraulic breaker" in section 8.

Check that the tool has received sufficient greasing.

Grease more frequently, if necessary.

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

Check the tool shank and tool bushing for wear. See "Replacing a tool on a hydraulic breaker" and "Replacing a tool bushing on a hydraulic breaker" in section 8.

Check the hydraulic hoses. Replace them if necessary.

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

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

Every 600 hours or once a year Have the hydraulic breaker thoroughly checked by your CASE Dealer.

SERVICING INSTRUCTIONS FOR SPECIAL APPLICATIONS Intervals between overhauls are much more frequent for the following applications: construction of tunnels using a hydraulic breaker, scale stripping, foundry cleaning, operation under water etc. For special applications consult your CASE Dealer.

6-5

SECTION 6 - SERVICING INTERVALS

CHECK

GREASE

Hydraulic breaker (optional)

1

10/50 (A)

2

7-20, 7-22

Engine oil level

1

10 (B)

7-20, 7-25

Coolant level

1

10 (B)

7-20, 7-35

Hydraulic reservoir level

1

10 (B)

7-28

Drain fuel tank sediment

1

8-5

Radiators and oil coolers

2

8-6

Fan/alternator belt tension

1

10 (B)

7-16, 8-21

CLEAN

6-5, 7-17

SERVICE POINTS

10 (B) 500

10 (B)

Tool quick coupler (optional)

4

(D)

7-35

Hydraulic system lines

-

50

8-23

Air conditioning

1

9-3

Battery change

2

7-14

Bucket linkages

2

50

5000

50 250 (Y)

7-20, 9-3

Batteries electrolyte level

2

250

Swing reduction gear level

1

250

7-20, 7-50

Travel reduction gears level

2

250

7-25

Tightening of clamps and radiator hoses

1

250 (F)

7-28

Fuel pre-filter filter element

1

7-35

Drain hydraulic reservoir sediment

1

7-44

Primary air filter element

1

8-1

Pad screw torque

-

250 (J)

8-4

Idler wheel and rollers

-

250

8-6

Fan/alternator belt tension

1

250

8-8

Cab protection (optional)

1

250 (J)

8-29

Screw and nut tightening torque

-

250 (J)

6-6

50

(E)

7-20, 7-48

250 250 250 (G)

1000 (H)

250 (G)

7-5

Turntable bearing

2

500

7-18

Turntable bearing teeth

1

500

7-22

Engine oil drain

1

7-22

Engine oil filter

2

500

7-28

Fuel filter filtering element

1

500

Attachment (except bucket linkages)

15

7-25

Draining the cooling system

1

7-35

Hydraulic fluid condition (*)

1

7-35

Hydraulic reservoir breather

1

1000

7-44

Secondary air filter element

1

1000 (M)

7-48

Swing reduction gear draining

1

8-7

Engine valve rocker clearances

-

1000 (P)

9-7

Alternator

1

1000 (P)

9-7

Starter motor

1

1000 (P)

7-7- 7-12

DRAIN BLEED

INTERVALS IN HOURS REPLACE

NO. OF POINTS

PAGE

INTERVALS

500

1000 (K) 1000 (L) 1000

1000 (N)

7-5, 7-19

Swing reduction gear

1

7-28

Fuel tank

1

2000 (X)

7-35

Inlet filter (*)

1

2000

7-35

Pilot filter (*)

1

2000 (Q)

7-35

Return circuit filter (*)

1

2000 (Q) (R)

7-50

Travel reduction gears draining

2

7-35

Main pump output hydraulic hoses

-

4000 (S)

7-35

Boom, dipper and bucket cylinder hydraulic hoses

-

4000 (S)

7-35

Hydraulic fluid (*)

1

5000 (T)

4-42

Safety valves

2

7-28

Fuel pre-filter bleed

1

7-28

Fuel filter bleed

1

7-28

Fuel supply pump filter

1

(V)

8-1

Tracks

2

(V)

8-7

Fuel tank filter

1

(V)

8-8

Fire extinguisher

1

8-9

Machine inspection

1

8-10

Cylinder sealing

-

(V)

8-14

Backhoe bucket shimming

1

(V)

DRAIN BLEED

GREASE

CHECK

REPLACE

INTERVALS IN HOURS CLEAN

SERVICE POINTS

NO. OF POINTS

PAGE

SECTION 6 - SERVICING INTERVALS

2000 5000

2000 (N)

(U) (C) (C) (V) (W) (V)

(V)

6-7

SECTION 6 - SERVICING INTERVALS (A) Have this checked by your CASE Dealer every 600 hours or once a year.

(B) Or every day.

(C) When the float reaches the level line (A).

(D) Check every week and whenever installing the quick coupler.

(E) To be checked every 6 months by a specialist.

(F) Or every 6 months.

(G) Or when the message "AIR FILTER" is shown on the message display screen.

(H) Or after cleaning 6 times.

(J) Check after the first 50 hours during the run-in period.

(K) If all these linkage points are not equipped with genuine parts, these points must be greased every 50 hours.

(L) Or every two years or twice a year (autumn/spring) if antifreeze is used.

(M) Or after the primary filter has been cleaned 3 times.

(N) Drain after the first 250 hours during the run-in period.

(P) Ask your CASE Dealer to check this.

(Q) Replace after the first 250 hours during the run-in period.

(R) If biodegradable fluid is used, it is imperative for the servicing interval to be reduced to 1000 hours.

(S) Or every 2 years, whichever comes first.

(T) If biodegradable fluid is used, it is imperative for the servicing interval to be reduced to 2000 hours.

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

(V) Periodically.

(W) Check once a month and have it checked every 6 months by a specialist.

(X) Or every year.

(Y) If all these linkage points are not equipped with genuine parts, these points must be greased every 10 hours.

NOTE: 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. (It is possible to increase this lapse of time. Consult your CASE Dealer). See "Control and function display console" in section 4. (*) IMPORTANT: If the machine is equipped with a hydraulic breaker, it is imperative that the servicing intervals are reduced, see "Replacing the hydraulic filters and fluid when a hydraulic breaker is used".

6-8

SECTION 7

52

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

!

WARNING

!

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

TRANSMISSION COMPONENT OIL Extreme pressure oil used for enclosed transmission components.

CASE/AKCELA: GEAR 135H EP (SAE 80W-90. API GL 5. MIL-L-2105 D. MS 1316.

ZF TE-ML 05A) GREASE

HYDRAULIC FLUID 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 (MS 1230. ISO VG 46. DIN 51524 PART 2 HV) Hot climates 0°C to +50°C CASE/AKCELA: AW HYDRAULIC FLUID 68 HV (MS 1216. ISO VG 68. DIN 51524 PART 3 CATEGORY HVLP)

CASE/AKCELA: MOLY GREASE 251H EP-M (NLGI 2) "Extreme Pressure" multipurpose grease with lithium soap and molybdenum disulphide.

CASE/AKCELA: MULTIPURPOSE GREASE 251H EP (NLGI 2) "Extreme Pressure" multipurpose grease with lithium soap and calcium.

CASE/AKCELA: PREMIUM GREASE EP2 (NLGI 2) "Extreme Pressure" multipurpose grease with lithium soap.

Hydraulic breakers CASE/AKCELA: MULTIPURPOSE GREASE 251H EP (NLGI 2).

Cold climates -25°C to +20°C CASE/AKCELA: AW HYDRAULIC FLUID 32 (MS 1216. ISO VG 32. DIN 51524 PART 2) Biodegradable fluid: -30°C to +40°C This yellow-coloured 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 (MS 1230. ISO VG 46. DIN 51524 PART 2 HV)

7-1

SECTION 7 - LUBRICATION/FILTERS/FLUIDS ENGINE OIL The CASE/AKCELA "No. 1 ENGINE OIL" is recommended for your engine. This oil ensures correct lubrication of your engine in all working conditions.

If the CASE/AKCELA Multigrade "No. 1 ENGINE OIL" cannot be obtained, use the oil corresponding to one of the following categories: ACEA E7. API CI-4.

CP02N001

1 OIL RANGE

1 2 2 3 3

CT02M001

2 (1) With mineral base (2) With semi-synthetic base (3) With synthetic base

7-2

SECTION 7 - LUBRICATION/FILTERS/FLUIDS FUEL The fuel used must comply with the Tier 3 emission control regulations.

Use grade No. 2-D 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 (below -7°C), it is provisionally approved to use a mixture of fuels No. 1-D and No. 2-D. Consult your fuel supplier or your CASE Dealer.

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.

Conditions applicable to diesel fuel The diesel fuel used must: -

be free from dust particles, even minute ones, have the proper viscosity, have a high cetane number, present great fluidity at low temperatures, have low sulphur content, have very little residual carbon.

Recommendations applicable to diesel fuel - JIS (Japanese Industrial Standard): No. 2 - DIN (Deutsche Industrie Normen): DIN 51601 - SAE (Society of Automotive Engineers) according to SAE-J-313C: No. 2-D - BS (British Standard) according to BS/2869-1970: Class A-1 - EN 590 - or fuel corresponding to these standards and stipulated in your country.

Using fuels other than those recommended can damage the fuel injection pump, the injector and other parts of the fuel supply system and the engine. The CASE company disowns any responsibility concerning this kind of damage, which is not covered by the guarantee. To avoid any damage to the engine fuel supply system, you are recommended to take the following safety messages into account: - Certain fuel suppliers mix used engine oil with diesel fuel.

Certain manufacturers of large engines allow them to do this. However, for your engine, do not use diesel fuel contaminated by engine oil. In addition to damaging the engine, this fuel can actually adversely affect the correct purification of exhaust gases. Before using diesel fuel, ask the supplier to confirm that it meets the above specifications.

IMPORTANT: For a proper use of fuel additives consult your supplier or your CASE Dealer. Do not inject fuel oil or gasoline, both fuels can damage the engine.

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

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.

IMPORTANT: It you use fuel which has a sulphur content of more than 2500 ppm, use API grade CF-4 or JASO grade DH-1 engine oil. However, if these specifications cannot be met, it is imperative that the engine servicing intervals are reduced to 250 hours (oil change, filters etc.). Every 3000 hours, the injectors and EGR (Exhaust Gas Recirculation) circuit parts must be checked and replaced by your CASE Dealer.

IMPORTANT: Use of any other fuel can cause serious breakdown and will cancel the guarantee.

7-3

SECTION 7 - LUBRICATION/FILTERS/FLUIDS ANTI-FREEZE/ANTI-CORROSION

ENVIRONMENT

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

CASE/AKCELA: PREMIUM ANTI-FREEZE (MS 1710)

Before carrying out any maintenance operation on this machine and before disposing of used fluids or lubricants, always think of the environment. Never throw oil or fluid on the ground and never place it in leaking receptacles.

For areas where the temperature goes down to -38°C, mix 50/50 with water.

IMPORTANT: Do not mix products of a different origin or brand.

The same product must be used when topping up the system.

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

FLUID AND LUBRICANT CAPACITIES AND SPECIFICATIONS ENGINE Type of oil ........................................................................................................................................"No. 1 ENGINE OIL" Capacity (with filter)............................................................................................................................................. 17 litres COOLING SYSTEM System capacity.................................................................................................................................................. 15 litres FUEL SYSTEM Reservoir capacity ............................................................................................................................................ 300 litres HYDRAULIC SYSTEM Type of fluid ........................................................................................................... "HYDRAULIC EXCAVATOR FLUID" Total system capacity........................................................................................................................................ 165 litres Reservoir capacity .............................................................................................................................................. 90 litres TRAVEL REDUCTION GEARS Type of oil .........................................................................................................."GEAR 135H EP" extreme pressure oil Capacity (per reduction gear): (CX160B) ........................................................................................................................................................... 5.8 litres (CX180B) ...............................................................................................................................................................5 litres SWING REDUCTION GEAR Type of oil .........................................................................................................."GEAR 135H EP" extreme pressure oil Capacity ................................................................................................................................................................ 5 litres

7-4

SECTION 7 - LUBRICATION/FILTERS/FLUIDS GREASE POINTS Type of grease .......................................................................................................... See "Fluids and lubricants" NOTE: The numbers within brackets mentioned on the right of the description indicate the number of lubrication points.

NOTE: After lubrication, refit the protective and indicating plastic caps to the grease fittings.

MACHINE

B C

A CT06K089

3 Every 500 hours Turntable................................................................... (2)

A

CT07A074

4

7-5

SECTION 7 - LUBRICATION/FILTERS/FLUIDS Turntable teeth ......................................................... (1) See "Greasing the turntable teeth".

B

CT07A075

5 Every 2000 hours Swing reduction gear .............................................. (1)

C

See "Greasing the swing reduction gear".

CT07A076

6

7-6

SECTION 7 - LUBRICATION/FILTERS/FLUIDS ATTACHMENT Monobloc boom/dipper

A

A

C

D

B

CT06K089

7 IMPORTANT: 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

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

B

CT07A075

9

7-7

SECTION 7 - LUBRICATION/FILTERS/FLUIDS Boom/dipper linkage................................................. (2)

C

CT06M023

10 Dipper cylinder top pin .............................................. (1)

D

CD01N023

11

7-8

SECTION 7 - LUBRICATION/FILTERS/FLUIDS Articulated boom/dipper (CX160B)

A

C

D

A

E F

G

A D

B

CT07A054

12 IMPORTANT: If the following linkage points are not equipped with original parts, these points must be lubricated every 50 hours.

Every 1000 hours Pre-boom bottom pin................................................ (2) Pre-boom cylinders top pin....................................... (2)

A

CT07B008

13 Pre-boom cylinders bottom pin ................................ (2)

B

CT07A075

14

7-9

SECTION 7 - LUBRICATION/FILTERS/FLUIDS Boom cylinder bottom pin......................................... (1)

C

CT07B008

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

D

CT07B008

16 Pre-boom/boom linkage ........................................... (1)

E

CT07B008

17 Boom/dipper linkage................................................. (2)

F

CT06M023

18 7-10

SECTION 7 - LUBRICATION/FILTERS/FLUIDS Dipper cylinder top pin.............................................. (1)

G

CD01N023

19

7-11

SECTION 7 - LUBRICATION/FILTERS/FLUIDS Offset-backhoe boom/dipper

A

D

B C CT07B004

20 IMPORTANT: 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) Offset linkage assembly 9-point grease fitting ......... (1) - Offset cylinder pins ............................................(4) - Dipper cylinder bottom pin...................................... (1) - Offset pivot .............................................................. (4)

A

CT07B003

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

B

CT07A075

22

7-12

SECTION 7 - LUBRICATION/FILTERS/FLUIDS Boom/dipper linkage................................................. (2)

C

CT07B005

23 Dipper cylinder top pin.............................................. (1)

D

CT07B006

24

7-13

SECTION 7 - LUBRICATION/FILTERS/FLUIDS Dipper/backhoe bucket

B

A CT06K089

C 25

IMPORTANT: If the following linkage points are not equipped with original parts, these points must be lubricated every 10 hours.

Every 250 hours Bucket linkages......................................................... (3)

A

IMPORTANT: If an accessory other than the bucket is installed, (hydraulic hammer, etc.) these points must be lubricated every 10 hours.

CD00E054A

26 IMPORTANT: 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

IMPORTANT: If an accessory other than the bucket is installed, (hydraulic hammer, etc.) these points must be lubricated every 10 hours.

CD00A054A

27 7-14

SECTION 7 - LUBRICATION/FILTERS/FLUIDS Bucket cylinder bottom pin ....................................... (1)

C

CT06K094

28

7-15

SECTION 7 - LUBRICATION/FILTERS/FLUIDS QUICK COUPLER TOOL LUBRICATION (optional) Every 50 hours Cylinder bottom pin................................................... (1) Locking system pivot................................................. (1)

CT02D344

29 Cylinder top ............................................................... (1)

CT02D345

30 Hook pivot ................................................................. (1)

CT02D346

31

7-16

SECTION 7 - LUBRICATION/FILTERS/FLUIDS GREASING THE HYDRAULIC BREAKER (optional) 1.

The tool shank must be well lubricated before installing.

2.

Press the grease gun between 3 to 5 times, at regular intervals, to grease the tool bushing and the tool.

3.

Adapt the intervals and the quantity of grease to the wear rate of the tool and to working conditions.

This can be anything between every two hours and once a day, depending on the type of material (rock/concrete) being broken.

Insufficient greasing or improper grease may cause: CT04K007

- abnormal wear of tool bushing, - tool breakage.

32

CORRECT GREASING While greasing, the hydraulic breaker must be standing upright resting on the tool to ensure that the grease will penetrate downwards between the tool and the bushing.

Do not fill the space between the piston and the tool with grease. A lower piston seal failure can result and the hydraulic breaker will eventually leak oil.

GREASE POINTS Use the following grease: CASE/AKCELA: MULTIPURPOSE GREASE 251H EP (NLGI 2).

Every 2 hours Tool shank................................................................. (1) Tool bushing.............................................................. (1)

CT02D243

33

7-17

SECTION 7 - LUBRICATION/FILTERS/FLUIDS GREASING THE TURNTABLE TEETH Grease capacity...................................................................................................................................................... 18 kg 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

CT07A075

34 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

35

7-18

SECTION 7 - LUBRICATION/FILTERS/FLUIDS GREASING THE SWING REDUCTION GEAR Grease capacity..................................................................................................................................................... 0.9 kg 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.

IMPORTANT: When greasing, the inner seal will be damaged if the air bleed plug (1) is not removed.

1

CT07A078

36 The grease point (2) is located on the upperstructure frame under the boom foot.

2

CT07A076

37

7-19

SECTION 7 - LUBRICATION/FILTERS/FLUIDS LEVELS Type of fluids and lubricants......................................................................................See "Fluids and lubricants" NOTE: The numbers within brackets mentioned on the right of the description indicate the number of levels.

Every 10 hours Engine oil................................................................... (1)

CT07A079

38 Coolant solution expansion reservoir....................... (1)

CT07A080 CT02C288

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

CT07A081

40

7-20

SECTION 7 - LUBRICATION/FILTERS/FLUIDS Every 250 hours Batteries.................................................................... (2)

CT07A082

41 Travel reduction gears .............................................. (2)

CD00E074

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

CT07A083

43

7-21

SECTION 7 - LUBRICATION/FILTERS/FLUIDS ENGINE SERVICE SPECIFICATIONS Engine oil level check......................................................................................................... Every 10 hours or every day Oil change ............................................................................................................................................. Every 500 hours Oil filter replacement............................................................................................................................. Every 500 hours Oil type ................................................................................................................................. See "Fluids and lubricants" Oil capacity.......................................................................................................................................................... 17 litres LEVEL 1.

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

2.

When the engine has been stopped for fifteen minutes, raise and lock the engine hood, remove the dipstick, wipe it with a clean cloth and insert it back in the guide tube as far as it will go. Then take it out again.

CT07A079

44 3.

If the level is situated between the marks (A) and (B) on the dipstick, the level is correct.

4.

If the oil level is at mark (A) (min) or below.

A

B CT05L023

45 5.

Remove the filling plug and add oil up to mark (B) (max) of the dipstick, install the plug.

NOTE: The level should not be higher than the mark (B) (maximum on the dipstick).

CT07A079

46

7-22

SECTION 7 - LUBRICATION/FILTERS/FLUIDS DRAINING, CHANGING THE OIL FILTER AND FILLING NOTE: Change the oil while the engine is still warm.

The oil will flow more easily.

Use the extension drain hose from the front boot.

1.

Place the machine on flat, level ground. Stop the engine, remove the starter switch key then open the hatch under the engine.

2.

Raise and lock the engine hood, remove the filling plug.

CT07A079

47 3.

Remove the protective cap from the engine housing drain valve.

4.

Screw the end of the extension drain hose onto the engine check valve, place the other end in a container of suitable capacity and allow the oil to flow out.

5.

Remove the extension drain hose and install the protective cap on the housing check valve. Place the extension drain hose in the front storage compartment.

CT07A084

48 6.

Clean the area around the filter located in the rear RH compartment, remove it using a filter wrench.

CT07A090

49

7-23

SECTION 7 - LUBRICATION/FILTERS/FLUIDS 7.

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 then tighten an extra half turn by hand.

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

CD00D301

50 9.

Fill the engine with new engine oil. Install the filling plug.

10. Run the engine for a few minutes and check that there are no leaks. Check the level again and top up if necessary.

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

CT07A079

51

7-24

SECTION 7 - LUBRICATION/FILTERS/FLUIDS COOLING SYSTEM SERVICE SPECIFICATIONS Expansion reservoir level check........................................................................................ Every 10 hours or every day Checking the tightening of clamps, of radiator hoses............................................Every 250 hours or every 6 months Draining the system (long duration) ........................................................................ Every 1000 hours or every 2 years Draining the system (with anti-freeze) (spring and autumn) ...................................................................... Twice a year System capacity...................................................................................................................................................15 litres

!

WARNING

!

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

!

WARNING

!

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

COOLANT SOLUTION Put only ethylene-glycol coolant solution in the cooling system. Use good quality ethylene-glycol that has a high boiling point, with no additives to prevent leakage.

Do not use non-approved anti-rust additives. Anti-rust additives and ethylene-glycol can mix and work against each other, thereby reducing anti-corrosion protection, forming deposits in the cooling system and causing damage to the cooling system and radiator.

Contact your CASE Dealer who will supply you with the suitable coolant.

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

On flat, 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".

1 2

CT07A080

52

7-25

SECTION 7 - LUBRICATION/FILTERS/FLUIDS DRAINING 1.

Remove the radiator plug.

!

WARNING

!

Do not remove the radiator cap when the engine is hot. The system is still under pressure and you could be scalded.

CT07A086

53 2.

Open the radiator drain valve located in the in the rear left-hand compartment.

CT07A087

54 3.

Open the drain plug located on the engine block.

NOTE: Have a receptacle of a suitable capacity ready.

CT06M028

55

7-26

SECTION 7 - LUBRICATION/FILTERS/FLUIDS RINSING 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.

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.

4.

Drain the system once more.

5.

Repeat Steps 1 to 4 until the water drained is clear.

FILLING 1.

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

CT07A086

56 2.

Fill the expansion reservoir to the "Full" mark and install the cap.

IMPORTANT: 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.

IMPORTANT: Do not fill the expansion reservoir above the "Full" mark.

CT07A080

57

7-27

SECTION 7 - LUBRICATION/FILTERS/FLUIDS FUEL SYSTEM SERVICE SPECIFICATIONS Fuel tank bleeding.............................................................................................................. Every 10 hours or every day Filter bleeding.........................................................................................................When the float reaches the level (A) Pre-filter bleeding...................................................................................................When the float reaches the level (A) Changing the pre-filter element............................................................................................................ Every 250 hours Changing the filter element................................................................................................................... Every 500 hours Cleaning the fuel tank ...................................................................................................Every 2000 hours or every year Fuel supply pump filter cleaning....................................................................................................................Periodically Fuel tank capacity............................................................................................................................................. 300 litres Type of fuel........................................................................................................................... See "Fluids and lubricants"

!

WARNING

!

Completely wipe off any spilt fuel after changing a filter element or bleeding the system.

DRAINING THE FUEL TANK 1.

Place a receptacle of a suitable capacity under the drain plug.

2.

Open the drain valve located at the bottom of the tank and drain the accumulated sediment and water.

3.

After draining, close the drain valve.

CD01K077A

58 PRE-FILTER BLEEDING When the float reaches the level line (A): 1.

Place a receptacle of a suitable capacity under the pre-filter.

2.

Loosen the bleed screw (1) and the plug (2) then drain the water and sediment.

3.

When the float (3) settles on the bottom, tighten the bleed screw (1) and the plug (2).

4.

Check for any signs of leak.

2

A

NOTE: In cold weather, the water can freeze on the top part of the bowl. Bleed after the ice has melted.

1 3 CT07A081

59 7-28

SECTION 7 - LUBRICATION/FILTERS/FLUIDS CHANGING THE PRE-FILTER ELEMENT

!

WARNING

!

If a fuel filter other than a genuine CASE filter is used, the guarantee will not be applied to a fault caused by the use of a wrong filter.

1.

Place a receptacle of a suitable capacity under the pre-filter.

2.

Close the valve on the supply line.

CT07A088

60 3.

Loosen the bleed screw (1) and the plug (2) then let the pre-filter drain.

2

1

CT07A081

61 4.

Clean around the pre-filter body then remove it using the wrench provided with the machine.

5.

Install the new filter element. Check the condition of the body seal, change it if necessary, apply a thin coat of oil on the seal then replace the body by rotating it until it is in contact with the pre-filter head.

6.

Tighten the body using the wrench, the tightening torque must be from 27.5 to 31.3 Nm.

CT07A089

62

7-29

SECTION 7 - LUBRICATION/FILTERS/FLUIDS 7.

Open the valve on the supply line.

8.

Bleed the system. See "Fuel system air bleed".

CT07A088

63 BLEED THE FILTER Proceed in the same manner as for the pre-filter.

See "Pre-filter bleeding".

CT07A090

64 CHANGING THE FILTER ELEMENT

!

WARNING

!

If a fuel filter other than a genuine CASE filter is used, the guarantee will not be applied to a fault caused by the use of a wrong filter.

Proceed in the same manner as for the pre-filter.

See "Changing the pre-filter element".

CT07A090

65

7-30

SECTION 7 - LUBRICATION/FILTERS/FLUIDS FUEL SYSTEM AIR BLEED It is necessary to bleed the fuel system when: -

The tank has been completely emptied.

The fuel pre-filter has been changed.

The fuel filter has been changed.

Parts of the fuel system have been removed for servicing or repair work.

- The machine has been in storage for a fairly long period.

1.

Loosen the air bleed screw (1).

2.

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

3.

Turn the priming pump piston (2) to the left in order to release the spring.

2

1

CT07A090

66 4.

Move the handle of the priming pump (2) up and down until fuel containing no air bubbles flows out of the air bleed screw (1).

5.

As soon as the fuel flows out, tighten the air bleed screw (1) and tighten the priming pump piston (2).

6.

Completely wipe off any spilt fuel. Start the engine and check for possible leakage.

!

WARNING

2

1

!

Completely wipe off any spilt fuel. It could cause a fire.

CT07A085&

67

CLEANING THE FUEL TANK 1.

Make sure that the tank is empty.

2.

Remove the cover located at the bottom of the tank and clean the inside of the tank.

3.

Put the cover back in position and fill the tank with fuel.

CD01K077A

68

7-31

SECTION 7 - LUBRICATION/FILTERS/FLUIDS CLEANING THE FUEL SUPPLY PUMP FILTER 1.

Located near the fuel pre-filter, place a receptacle of suitable capacity under the supply pump.

CT07A081

69 2.

Close the valve on the supply line then remove the supply pump.

CT07A088

70 3.

Open the pump body and extract the filter (2) and the seals (1) and (3).

4.

Clean the filter with compressed air. Check the filter and replace it if necessary. Replace the seals with new seals.

5.

2 4

Carefully clean the body (4) and the cover (5). No dirt must remain in the supply pump.

6.

Re-assemble, taking care to install the seals in the correct order then re-install the pump.

7.

Open the valve on the supply line.

8.

Bleed the system. See "Fuel system air bleed".

5 1 3 CT07B007

71

7-32

SECTION 7 - LUBRICATION/FILTERS/FLUIDS RELEASING PRESSURE IN THE HYDRAULIC SYSTEM IMPORTANT: Before carrying out any work on the hydraulic system, there should be no pressure in any of the circuits.

1.

Place the machine on flat, level ground, lower the attachment to the ground and stop the engine.

2.

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

CD00E060

72 3.

Push the function cancellation lever forward (safety bar in outward position).

CT06K030

73 4.

Operate the control levers from right to left and front to rear a dozen times approximately.

5.

Turn the starter switch key to the "OFF" position (shut down).

CT06K082

74

7-33

SECTION 7 - LUBRICATION/FILTERS/FLUIDS 6.

Press the button on top of the breather on the hydraulic reservoir to release any residual pressure.

CT07A091

75

7-34

SECTION 7 - LUBRICATION/FILTERS/FLUIDS HYDRAULIC SYSTEM SERVICE SPECIFICATIONS Check the hydraulic reservoir fluid level............................................................................. Every 10 hours or each day Check the lines ........................................................................................................................................Every 50 hours Draining water and sediment from the hydraulic reservoir.................................................................. Every 250 hours Check the condition of the hydraulic fluid........................................................................................... Every 1000 hours Change the reservoir breather filter element ..................................................................................... Every 1000 hours Clean the inlet filter ............................................................................................................................. Every 2000 hours Change the return filter....................................................................................................................... Every 2000 hours (after the first 250 hours during the run-in period) Change the pilot filter.......................................................................................................................... Every 2000 hours (after the first 250 hours during the run-in period) Change the main pump outlet hoses...................................................................... Every 2 years or every 4000 hours (whichever comes first) Change the boom, dipper and bucket cylinder hoses ............................................ Every 2 years or every 4000 hours (whichever comes first) Change the inlet filter.......................................................................................................................... Every 5000 hours Change the hydraulic fluid.................................................................................................................. Every 5000 hours Reservoir capacity ...............................................................................................................................................90 litres Total system capacity ........................................................................................................................................165 litres Oil type ................................................................................................................................. See "Fluids and lubricants" IMPORTANT: If biodegradable fluid is used, it is essential to reduce the following servicing intervals to the number of hours shown: Change the return filter....................................................................................................................... Every 1000 hours (after the first 250 hours during the run-in period) Change the hydraulic fluid.................................................................................................................. Every 2000 hours NOTE: If the machine is new or if a major component has been overhauled or changed in the hydraulic system, change the pilot filter and return filter after 50 hours of operation. After that, change these filters at the stipulated interval.

IMPORTANT: Every 1000 operating hours, it is necessary to have the hydraulic fluid analysed. Consult your CASE Dealer.

IMPORTANT: After changing the hydraulic fluid, it is necessary to bleed all air from the hydraulic components. See "Bleeding air from the hydraulic components".

IMPORTANT: If metal particles are found in the old filters, see your CASE Dealer.

!

WARNING

!

Before carrying out any service work on the hydraulic system it is necessary to allow it to cool down (the temperature should not be more than 40°C).

!

WARNING

!

Hydraulic fluid or grease injected into your skin can cause severe injury or death. Keep your hands and body away from any pressurized leak.

Use cardboard or paper to check for a leak. If fluid is injected into your skin, see a doctor immediately and have the fluid removed.

!

WARNING

!

Before carrying out any operation on the hydraulic filters or the hydraulic system, the pressure must be released from the system. Failure to observe this instruction can cause injury. See "Releasing pressure in the hydraulic system".

7-35

SECTION 7 - LUBRICATION/FILTERS/FLUIDS LEVEL IN THE RESERVOIR 1.

Place the machine on flat, level ground and place the attachment in the position shown. Stop the engine and remove the starter switch key.

CT06K089

76 2.

The oil should be in the middle of the indicator.

Add more oil if necessary. See "Filling the reservoir".

CT07A081

77 FILLING THE RESERVOIR 1.

Release all pressure in the hydraulic reservoir.

See "Releasing pressure in the hydraulic system".

2.

Clean the cover plate and the area around the plate. Remove the cover plate and add hydraulic fluid to the reservoir as required.

3.

Replace the cover plate seal if required and install the cover plate.

!

WARNING

!

Make sure that no contaminant (water, sand etc.) enters the reservoir during filling.

CT07A091

78

7-36

SECTION 7 - LUBRICATION/FILTERS/FLUIDS RESERVOIR SEDIMENT REMOVAL 1.

Release all pressure in the hydraulic reservoir.

See "Releasing pressure in the hydraulic system".

2.

Place a receptacle of a suitable capacity under the drain plug.

3.

Open the drain valve on the bottom of the reservoir and drain the sediment and water accumulated at the bottom of the reservoir.

4.

After draining, close the drain valve.

5.

Add hydraulic oil if necessary. See "Filling the reservoir".

CT06M029

79 PILOT FILTER REPLACEMENT Release all pressure in the hydraulic system. See "Releasing pressure in the hydraulic system".

Use a wrench to unscrew the filter and remove it.

Coat the seal of the new filter with a fine film of oil.

Install the new filter. Turn the filter until the seal comes into contact with the filter head then tighten an extra third of a turn by hand.

CT07A056

80

7-37

SECTION 7 - LUBRICATION/FILTERS/FLUIDS CLEANING AND REPLACEMENT OF THE INLET FILTER 1.

Release all pressure in the hydraulic reservoir.

See "Releasing pressure in the hydraulic system".

2.

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

CT07A091

81 3.

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

4.

Remove the inlet filter (4) and clean with solvent.

Dry it completely and check it for any damage. If there is any damage on the surface, replace it with a new one.

5.

Install a new O-ring (2) and install the inlet filter (4), spring (3) and rod assembly.

6.

Install the cover (1).

7.

Check the level of the hydraulic fluid and add more if necessary. See "Filling the reservoir".

1 2

3

NOTE: Install a new inlet filter every 5000 hours of operation or when the hydraulic fluid is changed.

4

CT07A048

82

7-38

SECTION 7 - LUBRICATION/FILTERS/FLUIDS RETURN FILTER REPLACEMENT 1.

Release all pressure in the hydraulic reservoir.

See "Releasing pressure in the hydraulic system".

2.

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

CT07A091

83 3.

Remove the cover (1) and O-ring (2).

4.

Take out the spring (3), valve (4) and filter (5).

1

5.

Install a new filter (5). Clean the spring (3) and valve (4) and install them.

2

6.

Check O-ring (2) and change it if worn or damaged.

7.

Install the cover (1).

8.

Check the level of the hydraulic fluid and add more if necessary. See "Filling the reservoir".

3 4

5

CT07A049

84

7-39

SECTION 7 - LUBRICATION/FILTERS/FLUIDS REPLACING THE RESERVOIR BREATHER FILTER ELEMENT

CT07A091

85 1.

Press the button (1) to release all pressure in the hydraulic reservoir.

2.

Remove the nut (2) and the cover (3) from the breather.

3.

Remove and discard the used filter element (4).

4.

Install a new element (4), making sure the seal (5) is facing upwards.

5.

Install the cover (3) as well as the nut (2).

1 2 3 5

4

XXXXXXXX

86

7-40

SECTION 7 - LUBRICATION/FILTERS/FLUIDS CHANGING THE HYDRAULIC FLUID 1.

Release all pressure in the hydraulic reservoir.

See "Releasing pressure in the hydraulic system".

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.

CT07A091

87 4.

Place a receptacle of a suitable capacity under the reservoir drain valve, open the tank drain valve and allow the remainder of the fluid to flow out.

5.

Change the inlet filter and the return filter. See "Cleaning and replacement of the inlet filter" and "Return filter replacement".

6.

Close the reservoir drain valve.

7.

Fill the reservoir with new hydraulic fluid. See "Filling the reservoir".

8.

Replace the cover plate seal if required and install the cover plate on the reservoir.

IMPORTANT: Before you start the engine, it is very important that you bleed air from all the hydraulic components. See "Bleeding air from the hydraulic components".

9.

CT06M029

88

Start and run the engine with no load for approximately five minutes.

10. Move each control several times to remove any air in the system.

11. Swing the upperstructure evenly left to right two complete turns or more.

12. Place the machine in position and then stop the engine.

13. Check the oil level in the hydraulic reservoir and add oil as required and check that there are no air bubbles in the hydraulic reservoir.

7-41

SECTION 7 - LUBRICATION/FILTERS/FLUIDS BLEEDING AIR FROM THE HYDRAULIC COMPONENTS IMPORTANT: After bleeding air from the components, stop the engine for five minutes and check there are no bubbles at the surface of the hydraulic fluid in the reservoir.

Hydraulic pump Using a solvent, clean the periphery of the air bleed plug. Loosen the air bleed plug, remove the plug if the fluid does not flow.

Fill the pump with new clean hydraulic fluid. Install and tighten the air bleed plug.

Start the engine and run it at low 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.

CT07A055

89 Attachment cylinders Start and run the engine at low idle speed. Extend and retract the attachment cylinder rods four or five times without bringing them to end of stroke. Then repeat the operation three or four times, this time bringing the cylinder rods to end of stroke.

Swing reduction gear Start and run the engine at low idle speed. Loosen the air bleed plug and make sure hydraulic fluid runs out. If necessary, stop the engine and add oil via the orifice.

Install the plug without tightening, then start and run the engine at low idle, leaving it to run until oil begins to run from the orifice. Tighten the air bleed plug completely. Swing the upperstructure at least twice completely to the right and twice completely to the left.

After complete bleeding, stop the engine for five minutes then check that there are no air bubbles in the hydraulic reservoir.

CT07A083

90

7-42

SECTION 7 - LUBRICATION/FILTERS/FLUIDS REPLACING THE HYDRAULIC FILTERS AND FLUID WHEN A HYDRAULIC BREAKER IS USED (optional) Hydraulic fluid - When using the hydraulic breaker, hydraulic fluid deteriorates more quickly than during ordinary digging. Check the hydraulic fluid level more frequently.

In addition, when changing the filters, also check the condition of the hydraulic fluid.

- Using the following table as a reference, determine the intervals for changing the hydraulic fluid and filters, depending on the frequency of use of the hydraulic breaker.

Percentage of use Interval in hours

100% 10

100

40% 600

10

(3)

(1)

300

20% 1500

10

(3)

(1)

600

10% 3000

10

(3)

(1)

800

Page

Service points

7-35

Hydraulic fluid

7-35

Return circuit filter

(3)

7-35

Inlet filter

(2)

7-35

Pilot filter

(3)

(3)

(3)

(3)

7-35

Hydraulic fluid condition

200 h

300 h

600 h

800 h

(1)

(3) (3)

(1) Check the level (2) Clean or replace

(2)

(3) (3)

(2)

4000

(3) (3)

(3)

(2)

(3)

(3) Replace

CHECKING THE HYDRAULIC SYSTEM PIPING Make sure there are no leaks from the hydraulic system hoses, pipes, plugs, connections and fittings and check that all nuts and screws are correctly tightened.

In the event of problems, repair, change or tighten the component(s) concerned.

7-43

SECTION 7 - LUBRICATION/FILTERS/FLUIDS AIR FILTER 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 changed before they are worn.

SERVICE SPECIFICATIONS Inspect and clean the primary element................................................................................................ Every 250 hours or when the message "AIR FILTER" is shown on the message display screen Change the primary element.............................................................................................................. Every 1000 hours or after cleaning 6 times Change the secondary element......................................................................................................... Every 1000 hours or after cleaning the main element 3 times IMPORTANT: The primary element can be cleaned.

The secondary element cannot be cleaned and must be changed.

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

REMOVING THE ELEMENTS 1.

Release the fasteners and remove the cover.

CT07A092

91 2.

Remove the primary element.

CT07A093

92

7-44

SECTION 7 - LUBRICATION/FILTERS/FLUIDS 3.

Remove the secondary element if it needs changing.

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

CT07A094

93 CLEANING THE PRIMARY ELEMENT IMPORTANT: Always protect your face before using compressed air.

If the primary element is dry: Blow compressed air from the inside towards the outside at very low pressure. The compressed air nozzle should be held at least 3 cm from the inside wall of the element. Cleaning is completed once no more dust comes out of the primary element.

IMPORTANT: Compressed air pressure should not exceed 7 bar.

CT02D120

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

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

IMPORTANT: Allow the element to dry completely before installing it. It is advisable to keep a spare, clean element ready for installation on the air filter while the cleaned element is drying.

PDE0088A

95

7-45

SECTION 7 - LUBRICATION/FILTERS/FLUIDS INSPECTING THE ELEMENT Check the element for damage by placing an inspection lamp inside the element.

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

PDE0378A

96 INSTALLING THE ELEMENTS 1.

Install the secondary element.

CT07A094

97 2.

Install the primary element.

CT07A093

98

7-46

SECTION 7 - LUBRICATION/FILTERS/FLUIDS 3.

Install the cover (with the word "TOP" at the top) and close the fasteners.

4.

Check that the dust ejector (1) under the filter is working correctly.

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

1 CT07A092

99

7-47

SECTION 7 - LUBRICATION/FILTERS/FLUIDS SWING REDUCTION GEAR SERVICE SPECIFICATIONS Oil level check ....................................................................................................................................... Every 250 hours Oil change ........................................................................................................................................... Every 1000 hours (after the first 250 hours during the run-in period) Greasing.............................................................................................................................................. Every 2000 hours Oil capacity.............................................................................................................................................................5 litres Oil type ................................................................................................................................. See "Fluids and lubricants"

!

WARNING

!

Wait till all components have cooled down before carrying out any operation.

1.

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

LEVEL

2 1

CT07A083

100 1.

Remove the dipstick (2). The oil should come up to the hatched area. If necessary, add more oil through the filler hole (1).

2.

Install the dipstick.

CP98N043

101

7-48

SECTION 7 - LUBRICATION/FILTERS/FLUIDS DRAINING AND REFILLING 1.

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

2.

Remove the dipstick (2) and the filler plug (1).

2 1

CT07A083

102 3.

Place a receptacle of a suitable capacity under the upperstructure frame, remove the oil drain plug (3) and allow the oil to flow out.

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

IMPORTANT: Check the condition of the drained oil.

If it contains metal filings or foreign matter, see your CASE Dealer.

4.

Install the drain plug (3).

5.

Add oil through the filler hole (1) until the level is correct.

6.

Install the dipstick (2) and the filler plug (1).

7.

Wait ten minutes and then use the dipstick (2) to check the oil level again. If necessary, add more oil through the filler hole (1).

3

CT07A095

103

NOTE: When greasing the swing reduction gear, see "Greasing the swing reduction gear".

7-49

SECTION 7 - LUBRICATION/FILTERS/FLUIDS TRAVEL REDUCTION GEARS SERVICE SPECIFICATIONS Oil level check ....................................................................................................................................... Every 250 hours Oil change ........................................................................................................................................... Every 2000 hours (after the first 250 hours during the run-in period) Oil capacity (per reduction gear) (CX160B) .......................................................................................................................................................... 5.8 litres (CX180B) .............................................................................................................................................................. 5 litres Oil type ................................................................................................................................. See "Fluids and lubricants" LEVEL 1.

Park the machine on flat, horizontal 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 (3) to release any residual pressure.

5.

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

3 2

1 CD00E074

6.

If necessary, replace the seal of plugs (2) and (3) then install the plugs.

7.

Repeat Steps 2 to 6 for the other travel reduction gear.

8.

Travel slowly with the machine and make sure there are no leaks.

7-50

104

SECTION 7 - LUBRICATION/FILTERS/FLUIDS DRAINING AND REFILLING 1.

Park the machine on flat, horizontal ground.

2.

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

3.

Shut down the engine and remove the starter switch key.

4.

Place a receptacle of suitable capacity under the travel reduction gear.

5.

Slowly loosen the plug (3) to release any residual pressure then remove the three plugs.

6.

Allow the oil to drain.

IMPORTANT: Check the condition of the drained oil.

If it contains metal filings or foreign matter, see your CASE Dealer.

7.

If required, replace the plug seals.

8.

Install the plug (1), fill with oil through the port (3) until oil comes up to the bottom edge of port (2), then install the plugs (2) and (3).

9.

Repeat Steps 2 to 8 for the other travel reduction gear.

3 2

1 CD00E074

105

10. Travel slowly with the machine and make sure there are no leaks.

7-51

SECTION 7 - LUBRICATION/FILTERS/FLUIDS

NOTES

7-52

SECTION 8

37

MAINTENANCE/ADJUSTMENTS TRACKS MAINTENANCE SPECIFICATIONS Clean............................................................................. Periodically and when the machine has been working in mud Check tension ................................................................................................................................................Periodically Check steel pad screw torques ............................................................................................................ Every 250 hours (after the first 50 hours during the run-in period) IMPORTANT: If the tracks are too tight, they wear quickly. If tracks are not tight enough, they wear quickly and the links can catch on the sprocket wheel or slide off the idler wheel or the sprocket wheel. Clean the tracks after work.

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

1.

Place the upperstructure at right angles to the undercarriage. Use the attachment to press on the ground and lower the boom until the track is raised off the ground.

2.

Turn the engine throttle button to maximum speed position.

CT06M031

1 3.

Use the travel speed selector to select high speed.

2

AUTO

n n/min

E

F

CT06K026

2

8-1

SECTION 8 - MAINTENANCE/ADJUSTMENTS 4.

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

5.

Repeat Steps 1 to 4 for the other track.

CT06M017

3 CHECKING THE TENSION 1.

Park the machine on flat, horizontal ground.

2.

Clean the tracks.

3.

Place the upperstructure at right angles to the undercarriage. Use the attachment to press on the ground and lower the boom until the track is raised off the ground.

4.

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

5.

Stop the engine and remove the starter switch key.

6.

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

The value must be between: CX160B: 260 mm and 280 mm.

CX180B: 280 mm and 300 mm.

7.

Adjust the tension if necessary and then lower the raised track to the ground.

8.

Repeat Steps 3 to 7 for the other track.

PE07531

4

8-2

SECTION 8 - MAINTENANCE/ADJUSTMENTS ADJUSTING THE TENSION NOTE: This operation is to be carried out after the tension has been checked.

To increase tension 1.

With the track raised, clean the grease fitting adaptor and the grease fitting.

2.

Connect the grease pump. Inject grease to obtain the right amount of track sag.

The value must be between: CX160B: 260 mm and 280 mm.

CX180B: 280 mm and 300 mm.

3.

Remove the grease pump and clean the grease fitting.

4.

Repeat Steps 1 to 3 for the other track.

CT06M032

5 To reduce tension 1.

With the track in raised position, slowly loosen the grease fitting adaptor by about three turns to allow grease to flow out of the cylinder.

!

WARNING

!

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

2.

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

The value must be between:

CT06M033

6

CX160B: 260 mm and 280 mm.

CX180B: 280 mm and 300 mm.

3.

Clean the grease adaptor and fitting and then lower the raised track to the ground.

4.

Repeat Steps 1 to 3 for the other track.

IMPORTANT: If the grease fitting adaptor is damaged, grease may leak out. Check the condition of the grease fitting adaptor regularly and replace it if necessary.

8-3

SECTION 8 - MAINTENANCE/ADJUSTMENTS TIGHTENING TORQUE OF THE TRACK PAD SCREWS IMPORTANT: Regularly check the tightening of the screws. Do not use the machine with the track pad screws loose, the screws may come off and damage the track.

The tightening torque of the screws must be: 804 Nm + 120°.

PE08316

7 IMPORTANT: Follow the prescribed order.

1

3

4

2

CS00E504

8

TRACK ROLLERS AND IDLER WHEELS MAINTENANCE SPECIFICATION Check .................................................................................................................................................... Every 250 hours The upper and lower rollers and idler wheels use a permanent floating seal type sealing mechanism.

The service life normally lasts until overhaul, but check visually from time to time before work for oil leakage. If oil leakage is found, component replacement is necessary. Consult your CASE Dealer.

CT07A096

9

8-4

SECTION 8 - MAINTENANCE/ADJUSTMENTS RADIATORS AND OIL COOLERS MAINTENANCE SPECIFICATIONS Check for leakage.............................................................................................................. Every 10 hours or every day Clean..................................................................................................................................................... Every 500 hours CLEANING 1.

Stop the engine and remove the starter switch key.

2.

Open the LH side door and block it with the supporting strut.

CT07A064

10 3.

Remove the wing nuts (1) and remove the protection grilles (2).

IMPORTANT: Always protect your face before using compressed air.

4.

Clean the radiators and the oil coolers: - Dry dust: use compressed air.

- Mud: use a water jet.

- Greasy dust: use perchlorethylene.

1

IMPORTANT: The use of trichlorethylene is strictly forbidden.

5.

Install the protective grilles (2) then install the wing nuts (1).

!

WARNING

2 CT07A097

11

!

Before undertaking any travel, make sure the LH side door is properly closed.

8-5

SECTION 8 - MAINTENANCE/ADJUSTMENTS FAN AND ALTERNATOR DRIVE BELT MAINTENANCE SPECIFICATIONS Visual check ....................................................................................................................... Every 10 hours or every day Check belt tension ................................................................................................................................ Every 250 hours CHECKING THE TENSION IMPORTANT: If the engine runs with the belt slack, the belt can slip in its housing and cause the engine to overheat or the battery to receive insufficient charge.

CT07A098

12 With engine shut down and the starter switch key removed, use your finger to exert a pressure of about 10 kg at the centre of the belt. The tension slack should be between about 6 and 8 mm.

NOTE: Check if there are any signs of wear damage to the pulleys or the belt. Check carefully to ensure that the belt is correctly positioned in the pulley grooves. If the belt is stretched, cracked or frayed, it must be replaced.

CS98M560

13 ADJUSTING THE TENSION Remove the retaining screws (1) and (2). Use the adjustment screw (3) to move the alternator outwards until belt tension is correct. Tighten the alternator mounting bolts (1) and (2).

3 1

2 CT07A098

14

8-6

SECTION 8 - MAINTENANCE/ADJUSTMENTS REPLACING THE BELT If the belt(s) break(s), the message "ALTERNATOR" is displayed on the screen. Shut down the engine, remove the starter switch key and change the belt.

Remove the retaining screws (1) and (2). Use the adjustment screw (3) to push the alternator inwards.

3

Remove the belts that are worn out.

1

Install one or two new belts.

Adjust the belts using the screw (3).

Retighten the retaining screws (1) and (2).

Run the engine for about an hour and then check the belt tension again.

2 CT07A098

15

ADJUSTMENT OF ENGINE VALVE ROCKER CLEARANCES MAINTENANCE SPECIFICATION Check .................................................................................................................................................. Every 1000 hours NOTE: Ask your CASE Dealer to check this.

FUEL TANK FILTER MAINTENANCE SPECIFICATION Clean filter ......................................................................................................................................................Periodically Remove the filter and clean it in diesel oil.

NOTE: To refill the fuel tank, see "Fluids and lubricants" in section 7.

CT07A099

16

8-7

SECTION 8 - MAINTENANCE/ADJUSTMENTS CAB PROTECTION (F.O.P.S.) (optional) MAINTENANCE SPECIFICATION Check .................................................................................................................................................... Every 250 hours (after the first 50 hours during the run-in period) MAINTENANCE AND CHECKS Check the retaining hardware, if necessary retighten the screws.

Check the absence of cracks, rust or holes in the protective structure and the components that constitute it.

Ageing, bad weather and accidents can cause damage. If you have even the slightest doubt regarding the condition of the structure, contact your CASE Dealer.

If the protective structure has suffered any accident, it is necessary to replace the damaged components of the structure in order to restore the initial protection.

CT04D008

FIRE EXTINGUISHER (not supplied)

17

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

MAINTENANCE SPECIFICATION Every month: Examine the fire extinguisher and make sure it is not damaged.

Every six months: Have an approved specialist empty the powder and refill the fire extinguisher.

Every year: Have an approved specialist examine the fire extinguisher.

8-8

CS98M573

18

SECTION 8 - MAINTENANCE/ADJUSTMENTS WELDING ON THE MACHINE Whenever carrying out a welding operation on the undercarriage or upperstructure carriage as authorized by the manufacturer and in accordance with his instructions, disconnect the batteries, disconnect the alternator B+ and D+ terminal wires and connect the welding apparatus earth cable to the component on which the welding operation is to be performed. Never connect the welding apparatus to the undercarriage when welding on the upperstructure (or vice-versa).

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

!

WARNING

!

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

INSPECTING AND CLEANING THE MACHINE MAINTENANCE SPECIFICATIONS Inspect and clean...........................................................................................................................................Periodically Or whenever oil or grease has been spilt on the machine. Clean off with steam or a high pressure water jet.

Take the opportunity during this operation to make a visual check of all the welded components (in case of appearance of cracks), the attachment linkages and check the teeth and tooth tips for correct retention and for wear. Look for any leaks and check the condition of all pipes and hoses.

8-9

SECTION 8 - MAINTENANCE/ADJUSTMENTS CHECKING FOR CYLINDER LEAKAGE A cylinder rod should be slightly oily. Check that there are no leaks after a period of work, when the whole hydraulic system is at normal operating temperature.

1.

Wipe clean the rod and bearing on the cylinder to be cleaned.

2.

Operate normally for five or ten minutes.

3.

Extend the cylinder rod.

4.

Carry out the leak test.

ROD APPEARANCE Dry Slightly greasy 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 the 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.

See your CASE Dealer

PLASTIC AND RESIN PARTS When cleaning the plastic windows, the console, the instrument panel, the indicators, etc. do not use gasoline, kerosene, paint solvents, etc. Only use water, soap and a soft cloth.

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

8-10

SECTION 8 - MAINTENANCE/ADJUSTMENTS 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.

Interchange and turn over the teeth regularly. Turn over the locking pin too.

NOTE: Do not wait for teeth or tooth tips to be completely worn through before changing them.

IMPORTANT: Never try to work with a missing tooth tip or a tooth tip which is worn through. The adaptor nose could be seriously damaged.

CT02D209

19

REPLACING A TOOTH ON THE BACKHOE BUCKET REMOVAL 1.

Remove the locking pin from the adaptor by striking it alternately at the rear (1) and at the front (2) until it is ejected.

1

2 CT02D205

20 INSTALLATION 1.

Fit the tip onto the adaptor, making sure it is correctly positioned, as indicated by the marks on the tip and the adaptor.

CT02D207

21

8-11

SECTION 8 - MAINTENANCE/ADJUSTMENTS 2.

Hammer in the locking pin assembly, as shown.

3.

Strike the front part (2) of the locking pin assembly and then alternately the rear (1) and front (2) parts until the assembly slots into the adaptor.

4.

Check that the locking pin assembly (1) is in the right position. The front part (2) of the assembly should be fully engaged in the adaptor nose.

1

2 CT02D208

22

REPLACING A BACKHOE BUCKET REMOVAL 1.

Place the bucket flat on flat, horizontal ground.

Operate the attachment controls so that the dipper/bucket linkage pin is not gripped by the weight of the dipper.

2.

Stop the engine and remove the starter switch key.

3.

Remove the retaining rings and pins.

CT02D210

23 4.

Remove the bucket pins.

CT02D211

24

8-12

SECTION 8 - MAINTENANCE/ADJUSTMENTS 5.

Start the engine, disengage the attachment from the bucket and save the linkage seals for re-use.

CT02D212

25 INSTALLATION 1.

Make sure the bucket is in a stable position.

2.

Install the linkage seals on the dipper bushing shoulders. Change them if necessary.

3.

Start the engine. Extend the bucket cylinder rod to bring it into its housing. Stop the engine and remove the starter switch key.

CT02D212

26 4.

Install the dipper/bucket linkage pin and then install the retaining pin and ring.

5.

Start the engine. Bring the bucket rod into its housing, stop the engine and remove the starter switch key.

CT02D213

27

8-13

SECTION 8 - MAINTENANCE/ADJUSTMENTS 6.

Install the dipper/bucket linkage pin and then install the retaining pin and ring.

7.

Push the seals back into their housings.

8.

Adjust the dipper/bucket shimming. See "Shimming the backhoe bucket".

9.

Grease the linkage pins.

CT02D210

28

SHIMMING THE BACKHOE BUCKET This mechanism is used to adjust the play between the dipper and the bucket in order to eliminate the play caused by wear. Check and adjust the play regularly.

SIDE PLAY ADJUSTMENT 1.

Place the bucket flat on flat, horizontal ground and stop the engine.

2.

Check the play (J) between the dipper and the bucket ear.

3.

If the play (J) exceeds 2 mm, 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 towards the dipper and takes up the play.

IMPORTANT: It is recommended to maintain a play of about 1.2 mm. If the play is insufficient, it may cause wear by friction or seizing.

IMPORTANT: The inner bushing has a lug which prevents it from turning. The cap (1) has an orifice on its inside surface. When installing the cap (1), make sure the lug is inside this orifice.

8-14

1

J 2 CD00E121

29

SECTION 8 - MAINTENANCE/ADJUSTMENTS REPLACING A TOOL ON A HYDRAULIC BREAKER (optional) REMOVAL 1.

Place the hydraulic breaker laying on hard, flat ground.

2.

Stop the engine and remove the starter switch key.

CT02D444

30 3.

Push the rubber plate upwards (if equipped).

Remove the retaining pins and plugs from both sides of the hydraulic breaker.

CT02D445

31 4.

Drive out the pins with a bronze or brass drift.

CT02D446

32

8-15

SECTION 8 - MAINTENANCE/ADJUSTMENTS 5.

Remove the tool. Use a lifting device if necessary.

NOTE: If the hydraulic breaker is still on the machine, it may be easier to stick the tool in the ground and lift the hydraulic breaker off the tool.

Make sure that the tool cannot fall.

CT02D447

33 INSTALLATION 1.

Check the tool bushing and oil seal for wear and replace them if necessary. See "Replacing a tool bushing on a hydraulic breaker".

2.

Clean and coat the tool and mounting pins with grease.

CT02D448

34 3.

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

4.

Install the mounting pins and make sure the tool is secure.

CT02D449

35 5.

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

CT02D450

36 8-16

SECTION 8 - MAINTENANCE/ADJUSTMENTS REPLACING A TOOL BUSHING ON A HYDRAULIC BREAKER (optional) REMOVAL 1.

Remove the tool. See "Replacing a tool on a hydraulic breaker".

2.

Drive out the mounting pins and plugs.

CT02D451

37 3.

Remove the tool bushing.

CT02D452

38

8-17

SECTION 8 - MAINTENANCE/ADJUSTMENTS INSTALLATION 1.

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

2.

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

CT02D453

39 3.

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

4.

Install the tool. See "Replacing a tool on a hydraulic breaker".

CT02D452

40

WEAR LIMITS ON A HYDRAULIC BREAKER (optional) TOOL BUSHINGS CB 150 model The wear limit is: Model CB 150 ............................................................... 97 mm

CT02D456

41

8-18

SECTION 8 - MAINTENANCE/ADJUSTMENTS CB 200S MOdel

3

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

2

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

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

1

See "Replacing a tool bushing on a hydraulic breaker".

CS99C629

42 TOOLS Model

Original dimension

Wear limit

CB 150 .......................Ø 95 mm.................... Ø 93 mm CB 200S....................Ø 115 mm................. Ø 113 mm For replacement, see "Replacing a tool on a hydraulic breaker".

CT02D455

43

8-19

SECTION 8 - MAINTENANCE/ADJUSTMENTS REPLACING A HYDRAULIC BREAKER (optional) REMOVAL 1.

Place the hydraulic breaker laying on hard, flat ground.

2.

Stop the engine and remove the starter switch key. Release all pressure in the hydraulic system.

See "Releasing pressure in the hydraulic system" in section 8.

3.

Place a receptacle of a suitable capacity under the hydraulic lines (1). Close the shut-off valves (for opening or closing the circuit) on the lines (if equipped). Disconnect the hoses from the tubes.

Plug if necessary.

4.

Remove the retaining hardware (this can vary depending on the mounting arrangement).

5.

Remove the connecting rod/hydraulic breaker linkage pin (2) and the dipper/hydraulic breaker linkage pin (3).

6.

Operate the machine controls to free the hydraulic breaker.

INSTALLATION 1.

Use the attachment controls to engage the dipper in the hydraulic breaker.

2.

Stop the engine and remove the starter switch key. Release all pressure in the hydraulic system.

See "Releasing pressure in the hydraulic system" in section 8.

3.

Install the dipper/hydraulic breaker linkage pin (3).

Connect the hoses to the hydraulic breaker.

4.

Operate the connecting rod control so as to engage it in the hydraulic breaker, then stop the engine and remove the starter switch key.

5.

Install the connecting rod/hydraulic breaker pin (2) then install the shaft retainer pins.

6.

Open the shut-off valves (for opening or closing the circuit) on the lines (1) (if equipped).

7.

Grease the linkage pins.

8-20

1

3

2 CT02D444

44

SECTION 8 - MAINTENANCE/ADJUSTMENTS CHECKING THE QUICK COUPLER LATCHING HOOK OPENING (optional) MAINTENANCE SPECIFICATION Check ...................................................................................................................................................... Weekly and each time the quick coupler is installed IMPORTANT: It is imperative to carry out this check once a week and each time the quick coupler is installed.

1.

Place the switch in unlocking position. The audible alarm device will sound.

See "Quick coupler locking and unlocking switch" in section 4.

CT06M006

45 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.

CT02C242

46

8-21

SECTION 8 - MAINTENANCE/ADJUSTMENTS 3.

Check the opening measurement (S) of the latching hook.

1 2

Under no circumstances may the measurement (S) exceed Locking bar resting on surface (1) .................................................................. 128.8 mm (2) ....................................................................... 97 mm (3) .................................................................... 54.5 mm

3

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.

!

WARNING

!

If the measurement (S) exceeds the maximum authorized, do not use the quick coupler and see your CASE Dealer.

INCORRECT OPERATION OF THE QUICK COUPLER IMPORTANT: Make sure that the attachment is resting on the ground. Shut down the engine and remove the starter switch key before carrying out one of the following checks.

If the quick coupler does not work correctly, check the following items: - That no pin is broken, bent or lost.

- That the cylinder is not damaged or bent.

- That there are no leaks from hydraulic hoses, etc.

If the problem persists after all these checks, consult your CASE Dealer.

!

WARNING

!

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

Modification of the quick coupler without prior authorization can cause serious injury. Do not carry out any modification without authorization from your CASE Dealer.

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

8-22

S CS00J511

47

SECTION 8 - MAINTENANCE/ADJUSTMENTS AIR CONDITIONING MAINTENANCE SPECIFICATION Clean the intake filter ...............................................................................................................................Every 50 hours Clean the air recycling filter .....................................................................................................................Every 50 hours Replace the filters ............................................................................................................................... Every 5000 hours Have checked by a specialist .................................................................................................................Every 6 months The components of the air conditioning system need servicing at regular intervals. Make sure these intervals are respected, in order to ensure the air conditioning functions correctly and with maximum effectiveness. The air conditioning system contains gas which is subject to strict legislation. Any defect in the system must be fixed rapidly.

!

WARNING

!

Never try to service the air conditioning system yourself. For any service work, consult your CASE Dealer.

NOTE: Operate the air conditioning system at least once a week, if only for a short time. See "Heating, ventilation or air-conditioning control" in section 4.

INSPECTION In order to ensure the air conditioning functions correctly, inspect the air conditioner using the procedure outlined below before 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.

CHECKING THE BELT TENSION Use your finger to exert pressure of around 10 kg on the centre of the drive belt. The tension slack should be between about 6 and 8 mm. If necessary, adjust the belt tension.

CHECKING THE LINES Make a visual check of the lines and make sure there are no accumulations of dust, grease, etc.

CT07A100

48

8-23

SECTION 8 - MAINTENANCE/ADJUSTMENTS CLEANING THE AIR INTAKE AND AIR RECYCLING FILTERS 1.

Loosen the screws (2) and remove the screw (1) as well as the cover plate (3) located in the air filter compartment.

1

3 2 2 CT07A101

49 2.

Remove the screws (4) and open the panel (5).

4

5 CT06K111

50 3.

Remove the filter and clean it with compressed air.

Replace the filter if it is damaged.

IMPORTANT: Always protect your face before using compressed air.

4.

Install the filter in its housing with the seal (6) on the inside.

5.

Close the panel (5) and install the screws (4).

6.

Install the cover plate (3), the screw (1) and retighten the screws (2).

6

CT06K112

51

8-24

SECTION 8 - MAINTENANCE/ADJUSTMENTS CLEANING THE AIR RECYCLING FILTER 1.

To access the filter, open the panel located behind the operator’s seat.

CT06K036

52 2.

Remove the filter and clean it with compressed air.

Replace the filter if it is damaged.

IMPORTANT: Always protect your face before using compressed air.

3.

Install the filter in its housing by following the direction of installation then close the panel.

CT06K113

53 CHECKING THE CHARGE STATE OF THE SYSTEM 1.

Turn on the air conditioning system, increase engine speed slightly (1400 to 1600 rpm) and look for bubbles through the sight glass.

CT07A102

54

8-25

SECTION 8 - MAINTENANCE/ADJUSTMENTS 2.

This check should be made approximately one minute after turning on the air conditioning.

A

(A) Very few bubbles observed, then transparent at first, then whitish: "Normal".

B

C

(B) The bubbles are numerous: check the unions and consult your CASE Dealer.

(C) No bubbles are visible: check the unions and consult your CASE Dealer.

CS00E555

55 3.

Check if the hydraulic line and air-conditioning hose connectors are dirty or dusty.

CT02D235

56

8-26

SECTION 8 - MAINTENANCE/ADJUSTMENTS ENGINE TROUBLESHOOTING NOTE: This section shows how to easily diagnose problems relating to the engine and describes the solutions to be adopted. If you are unable to determine the cause of the failure, or if the latter is difficult to rectify, contact your CASE Dealer.

PROBLEM

Engine does not start.

POSSIBLE CAUSE

SOLUTION

Defective starter switch (starter does not run)

Check starter switch

Defective rotation of starter (starter rotates slowly)

Discharged batteries, starter problems, contaminated or loose wiring connectors

Incorrect viscosity of engine oil

Inspect and replace as necessary

Incomplete air bleeding of fuel system

Completely bleed air

Engine too cold (cold weather)

Preheat the intake air or warm up the coolant

No fuel in fuel tank

Refill

Poor fuel quality

Inspect and replace as necessary

Fuel filter clogged

Clean or replace

Possible seizure in engine Low compression

See your CASE Dealer

Defective fuel injection pump Engine stops during operation.

No fuel in fuel tank

Refill

Fuel filter clogged

Clean or replace

Air in the fuel system

Retighten fuel in line connections

Low oil

Refill

Oil filter clogged

Replace oil filter

Low oil viscosity

Replace with oil of viscosity to match temperature

Oil leakage from connections

Tighten connections

Incorrect oil pressure.

Defective oil pressure switch See your CASE Dealer Incorrect functioning of oil pump

Exhaust from engine is white or blue.

Excessive oil

Disassemble and clean/replace parts

Excessively low oil viscosity

Replace with oil that has correct viscosity

Excessive cooling by radiator

Adjust

Incorrect fuel injection timing See your CASE Dealer Low compression

8-27

SECTION 8 - MAINTENANCE/ADJUSTMENTS

PROBLEM

Exhaust from engine is black or dark grey.

POSSIBLE CAUSE

SOLUTION

Incorrect fuel

Replace with correct fuel

Incorrect valve clearance

Adjust

Insufficient air intake (air filter clogged)

Clean or replace the air filter

Defective fuel injection pump See your CASE Dealer Low compression Incorrect fuel

Replace with correct fuel

Insufficient air intake

Clean or replace element

Defective fuel injection pump Excessive fuel consumption.

Incorrect spray from fuel injection nozzle See your CASE Dealer Incorrect fuel injection timing Low compression Excessive oil

Drain oil to proper level

Low oil viscosity

Replace with oil of viscosity to match temperature

Oil leakage

Retighten and replace parts if necessary

Worn cylinder piston ring

See your CASE Dealer

Poor fuel quality

Replace

Damage inside muffler

Replace

Low coolant

Refill

Coolant leakage

Repair

Worn or damaged belt

Replace

Incorrect mixture of anti-freeze solution

Replace

Excessive engine oil consumption.

Unusual noise (fuel or mechanical).

Engine overheating (coolant temperature is too high).

Defective radiator Broken fan Defective thermostat

See your CASE Dealer

Defective water pump Defective water temperature gauge

Defective battery charge.

Incorrect belt tension

Adjust

Electrical wiring problems

Repair

Defective battery

Replace

Defective regulator See your CASE Dealer Defective alternator

8-28

SECTION 8 - MAINTENANCE/ADJUSTMENTS HARDWARE TORQUE INSPECTION MAINTENANCE SPECIFICATION Check .................................................................................................................................................... Every 250 hours (after the first 50 hours during the run-in period) 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 Screw (Ø)

Wrench (mm)

Torque setting (Nm)

Travel reduction gear (*)

M16

24

267-312

Drive sprocket (*)

M16

24

267-312

Idler wheel (*)

M16

24

267-312

Upper roller (*)

M20

30

521-608

Lower roller (*)

M18

27

371-432

Chain guide (*)

M18

27

400-462

Track pad

M20

30

804 + 120°

Counterweight

M33

50

1862-2058

Turntable (undercarriage)

M20

30

468-545

Turntable (upperstructure)

M20

30

468-545

Swing reduction gear (*)

M20

30

539-630

Engine (*)

M16

24

265-314

Engine mounts (*)

M12

19

64-74

Radiator

M12

19

64-74

Hydraulic pump (*)

M10 M16

17 hexagonal

64-73 223-247

Hydraulic reservoir (*)

M16

24

232-276

Fuel tank (*)

M16

24

232-276

Control valve

M16

24

330-360

M12/M16

19/24

88-107/109-127

Cab

M16

24

245-294

Batteries

M10

17

20-29

Component

Hydraulic swivel (*)

NOTE: Use Loctite 262, or the equivalent, on screws marked (*).

8-29

SECTION 8 - MAINTENANCE/ADJUSTMENTS

NOTES

8-30

SECTION 9

10

ELECTRICAL SYSTEM FUSES IMPORTANT: Before changing fuses or relays, turn the starter switch key to the "Shut down" position.

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

To access the fuse box, open the panel located behind the operator’s seat.

CT06K036

1 To access the fuses, remove the cover of the box.

CT06K037

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

NOTE: To remove or install a fuse, use the notch in the upper right-hand corner of the cover.

A23955

3

9-1

SECTION 9 - ELECTRICAL SYSTEM FUSE FUNCTIONS (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) Working lights ................................................. 15 A

KHP12180

10A

20A

11

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

1 2 3

7 8 9 10

13

17 18 19 20

CT06K073

4

9-2

SECTION 9 - ELECTRICAL SYSTEM BATTERIES MAINTENANCE SPECIFICATION Checking the charge state.......................................................................................................................Every 50 hours Electrolyte level check .......................................................................................................................... Every 250 hours NOTE: When starting the machine with booster batteries, see "Connecting booster batteries".

!

WARNING

!

Before any operation on the components of the electrical circuit, put the starter switch key in the "Off" (shut down) position. When disconnecting batteries, always disconnect the negative (-) cable first. When reconnecting batteries, always connect the negative (-) cable last.

!

WARNING

!

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

Antidote: EXTERNAL: rinse thoroughly with water and remove soiled clothes.

INTERNAL: do not induce vomiting. Rinse the mouth out with water. Seek medical advice.

EYES: rinse thoroughly with water for 15 minutes and seek medical advice.

!

WARNING

!

A spark or a naked light can cause the hydrogen in a battery to explode. To prevent explosion, proceed as follows: - When disconnecting battery cables, always disconnect the negative cable (-) first.

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

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

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

!

WARNING

!

Batteries give off explosive gases. Keep all naked flames, sparks and cigarettes away. Ensure adequate ventilation when charging batteries or when using in a confined place. Always protect your eyes when working near batteries.

9-3

SECTION 9 - ELECTRICAL SYSTEM To access the batteries, open the LH side door then remove the skid plate.

CT07A068

5 CHECKING THE CHARGE STATE OF A MAINTENANCE-FREE BATTERY The charge indicator on the battery shows the state of charge of the battery.

If the colour is: Green; the charge is correct.

Black; insufficient charge. Recharge the battery until the indicator turns green.

Transparent (colourless); replace the battery as soon as possible.

CT07A103

6 CHECKING THE ELECTROLYTE LEVEL OF A MAINTENANCE-TYPE BATTERY Remove the cell caps and check the level in each batteries cell. The level should be between 10 and 15 mm above the plates. Add distilled water if necessary, then install the cell caps.

IMPORTANT: When adding distilled water at temperatures below 0°C, the batteries must be charged or the engine run for two hours approximately in order to ensure that the distilled water and the electrolyte are properly mixed.

NOTE: Make sure the battery terminals are clean and coated with grease and that the cables are properly tightened.

CT06M036

7

9-4

SECTION 9 - ELECTRICAL SYSTEM CHANGING A BATTERY 1.

Remove the terminal protection caps, disconnect cables (negative terminals) and then cables (positive terminals). Remove the anti-sulphate pellets and the battery clips.

2.

Install a new battery, put back its clips.

3.

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

4.

Install new anti-sulphate pellets, reconnect positive cable ends to positive terminals and then negative cable ends to negative terminals. Install the terminal protection caps.

CT06M037

!

WARNING

!

8

Do not invert battery terminals. Connect positive cable ends to positive terminals (+) and negative cable ends to negative terminals (-).

5.

Install the skid plate.

!

WARNING

!

Always store batteries in a safe place, out of the reach of children.

!

WARNING

!

Never touch battery terminals with the hands as electrolysis can take place within the human body and damage vital organs.

9-5

SECTION 9 - ELECTRICAL SYSTEM CONNECTING BOOSTER BATTERIES

!

WARNING

!

Connecting auxiliary cables wrongly or short-circuiting batteries terminals can cause an accident. Connect auxiliary starting cables as per the following instructions.

Make sure that the booster battery voltage corresponds to the voltage system of the machine (24 volts).

1.

Remove the terminal sleeves.

2.

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

3.

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

4.

Start the engine.

5.

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

6.

Install the terminal sleeves.

9-6

SECTION 9 - ELECTRICAL SYSTEM ALTERNATOR MAINTENANCE SPECIFICATION Check .................................................................................................................................................. Every 1000 hours

!

WARNING

!

Whenever carrying out a welding operation on the machine (authorised by the manufacturer and in accordance with his instructions) or any repairs on the electrical system, disconnect the B+ and D+ wires from the alternator. When reconnecting, check the markings on the wires.

IMPORTANT: Do not use steam cleaning equipment or a cleaning solvent to clean the alternator.

Ask your CASE Dealer to check the alternator.

NOTE: Make sure that the terminal protectors are correctly installed.

CT07A098

9

STARTER MOTOR MAINTENANCE SPECIFICATION Check .................................................................................................................................................. Every 1000 hours Ask your CASE Dealer to check the starter motor.

NOTE: Make sure that the terminal protectors are correctly installed.

CT07A104

10

9-7

SECTION 9 - ELECTRICAL SYSTEM REPLACING A BULB OPERATOR’S COMPARTMENT LIGHTING 1.

Remove the cover.

2.

Remove the bulb and install a bulb of the same wattage (10 W).

3.

Install the cover.

CT06M039

11 ATTACHMENT WORKING LIGHT 1.

Remove the 4 retaining screws.

CD00E124

12 2.

Tilt the working light and disconnect the plug.

CD00E125

13

9-8

SECTION 9 - ELECTRICAL SYSTEM 3.

Pull the clip outwards, remove the bulb and install a bulb of the same wattage (70 W).

IMPORTANT: Never put your fingers on a tungsten iodide bulb.

4.

Install the clip and reconnect the plug.

5.

Put the working light back into position and install the mounting screws.

CD00E126

14 UPPERSTRUCTURE AND CAB HEADLIGHT 1.

Open the front box.

CT07A062

15 2.

Remove the switch bracket to access the headlamp.

CT07A072

16

9-9

SECTION 9 - ELECTRICAL SYSTEM 3.

Disconnect the plug.

CD00E128

17 4.

Remove the four screws and tilt the headlight.

CD00E129

18 5.

Pull the clip outwards, remove the bulb and install a bulb of the same wattage (70 W).

IMPORTANT: Never put your fingers on a tungsten iodide bulb.

6.

Install the clip, put the headlamp back in position and install the screws and the plug.

7.

Put the windshield washer reservoir back in place.

CD00E130

19

9-10

SECTION 10

2

STORAGE STORING THE MACHINE PREPARATION FOR STORAGE

PERIODIC 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 or, if not possible, outside and covered with a tarpaulin. Before storing the machine, carry out the following operations:

Every month, check:

1.

2.

3.

4.

1.

The battery charge and recharge the batteries if required.

2.

The levels and top up if necessary.

Clean the machine.

3.

Make sure that the machine has no damaged or missing parts. Replace them if necessary.

The condition of all lines, connectors and clamps (rust). Grease if necessary.

4.

The condition of the paintwork. Apply a coat of anti-rust treatment where necessary.

5.

Unplug the air filter inlet and the exhaust pipe.

6.

Run the engine at low speed following the starting up procedure and operate the attachment, swing and travel controls.

Retract the cylinder rods as for as possible and lower the boom until the attachment is resting on the ground.

Grease the machine thoroughly. The exposed surfaces of the cylinder rods should be greased or covered with a protective film. See your CASE Dealer.

!

WARNING

!

NOTE: When the machine resumes service, the film will disappear automatically.

Avoid running the engine in a confined place. Make sure there is adequate ventilation at all times..

5.

7.

The grease on the cylinder rods.

8.

Plug the air filter inlet and the exhaust pipe.

While the engine is still warm, drain the oil sump, replace the oil filter and fill with specified oil.

Check the oil level and add more if necessary.

6.

Clean or replace the air filter element.

7.

Check the level of coolant solution. If the machine is within 100 hours of the next scheduled coolant change, change the coolant now.

8.

Remove the batteries, clean the battery housings and make sure not to leave any traces of acid.

Store the batteries safely in a cool and dry location, where the temperature is higher than 0 °C or disconnect the cable from the negative (-) terminal.

9.

Paint any areas where the paintwork is not good.

10. Plug the air filter inlet and the exhaust pipe.

11. Remove the starter switch key and place a "Do not operate" label on the right-hand control arm and then place the function cancellation lever in the central position (safety bar in inward position).

12. Lock the hoods, side doors and the cab door.

10-1

SECTION 10 - STORAGE STARTING UP AFTER STORAGE 1.

Drain the fuel tank, the pre-filter and the fuel filter, replace the filter elements if necessary.

2.

Fill the fuel tank with suitable fuel, see "Fluids and Lubricants" in section 7.

3.

Install the batteries or reconnect the cable to the negative (-) terminal.

4.

Grease the machine thoroughly.

5.

Check the condition of the fan drive belt and replace it if necessary.

6.

Check the condition of the air conditioning drive belt and replace it if necessary.

7.

Check the level of the cooling system and add more coolant if necessary.

8.

Check the hydraulic fluid level and add more fluid if necessary.

9.

Check the travel reduction gears and swing reduction gear oil level and add more oil if necessary.

10. Clean the cylinder rods.

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

!

WARNING

!

Before starting the engine, make sure that all controls are in neutral position. This prevents the machine from moving unexpectedly.

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

13. Keep a careful watch on all systems display panel lamps and indicators.

!

WARNING

!

Check the machine for leaks or for any parts that are broken, defective or missing.

!

WARNING

!

Avoid running the engine in a confined place. Make sure there is adequate ventilation at all times.

10-2

SECTION 11

16

SPECIFICATIONS ENGINE Latest "common rail" engine, in conformity with the European requirements applicable to low fumes emission, in accordance with the directive 97/69/EC 3A. Make and type ...........................................................................................................................ISUZU AI-4JJ1X Common rail, turbo, intermediate cooler, fuel cooler ......................................................................................yes Injection ..........................................................................................................................electronically controlled Number of cylinders........................................................................................................................................... 4 Bore/stroke ........................................................................................................................ 95.4 mm x 104.9 mm Displacement........................................................................................................................................2999 cm3 Cooling ...................................................................................................................................................by water Battery starting ......................................................................................................... 2 12/24 V batteries, 72 A/h WORKING CONDITIONS Speed ...................................................................................................................................................2200 rpm EEC 80/1269 power ...................................................................................................................89.2 kW/120 hp Engine oil capacity......................................................................................................................................... 17 l Fuel tank capacity........................................................................................................................................ 300 l 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 2200 rpm) .................................................................................................2 x 142 l/min Fixed flow pump (pilot circuit).

Max. flow ................................................................................................................................................ 22 l/min Working pressure.

Attachment/power boost ...................................................................................................................343/363 bar 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 .......................................................................................................................... 90 l Total hydraulic system capacity ................................................................................................................... 165 l 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.

Boom/dipper load holding valves.

11-1

SECTION 11 - SPECIFICATIONS SWING Fixed flow, piston-type pump.

Automatic disk brake.

Upperstructure swing speed ................................................................................................................. 11.5 rpm TRAVEL Two speed hydraulic motors with axial pistons.

Planetary reduction gears.

Low speed.............................................................................. (CX160B) 0 to 2.8 km/h; (CX180B) 0 to 2.3 km/h High speed............................................................................. (CX160B) 0 to 5.4 km/h; (CX180B) 0 to 4.0 km/h Gradeability.................................................................................................................................................. 70% ATTACHMENT Crowd force....................................................................................................................................... 11 800 daN Break-out force (with 2.20 m dipper).................................................................................................... 9500 daN Break-out force (with 2.60 m dipper).................................................................................................... 8400 daN Break-out force (with 3.00 m dipper).................................................................................................... 7700 daN

UNDERCARRIAGE One-piece frame with welded components.

Lubricated track rollers and idler wheels.

Grease cylinder track tension system.

Steel tracks (CX160B) ........................................................................................500 mm, 600 mm and 700 mm Steel tracks (CX180B) ........................................................................................600 mm, 700 mm and 800 mm Ground pressure (with 600 mm track pads)........................................................................................... 0.40 bar Ground pressure (with 600 mm track pads and articulated boom) (CX160B) ....................................... 0.41 bar

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, dual horn.

Safety valves with overload indicator ...................................................................................................... optional Inertia reel type safety belt.

Fire extinguisher ..................................................................................................................................... optional

11-2

SECTION 11 - SPECIFICATIONS OPERATOR’S COMPARTMENT Deluxe operator’s seat with armrests, inertia type safety belt, multi-position adjustment and headrest (vibration level III/ISO 7096, 2000 Class EM 3 or EM 4 depending on the model).

Hydraulically assisted controls.

Attachment and swing .................................................................................................................2 control levers Travel ...............................................................................................................................................2 foot pedals 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 upperstructure.................................................................................................................24 V, 70 W One on attachment ..................................................................................................................... 24 V, 70 W Two on cab.................................................................................................................................. 24 V, 70 W

NOISE LEVELS Guaranteed by the manufacturer.

Outside the operator’s compartment (Lwa).

Acoustic power 100 decibels, in accordance with the 2000/14/EC directive.

Inside the operator’s compartment (Lpa).

Acoustic power 74 decibels in accordance with the ISO 6394 standard.

VIBRATION LEVEL INSIDE THE CAB Upper members............................................................................................................ level lower than 2.5 m/s2 Body ............................................................................................................................. level lower than 0.5 m/s2

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.

Windshield protection grid (optional).

Cab protection (optional).

11-3

SECTION 11 - SPECIFICATIONS WEIGHTS With monobloc boom, 2.60 m dipper, 660 l backhoe bucket, 600 mm pads, operator and full fuel tank ............................................................ (CX160B) 17 000 kg; (CX180B) 17 900 kg With articulated boom, 2.60 m dipper, 660 l backhoe bucket, 600 mm pads, operator and full fuel tank ............................................................................................... (CX160B) 17 500 kg

BOOMS Monobloc boom length (CX160B and CX180B) ...............................................................................................5.15 m Articulated boom length (CX160B) ...................................................................................................................4.98 m

DIPPERS Length .......................................................................................................................2.20 m, 2.60 m and 3.00 m

BACKHOE BUCKETS GENERAL PURPOSE SAE capacity (l)

270

390

505

660

750

850

950

Width (mm)

500

600

750

900

1000

1100

1200

SAE capacity (l)

660

750

850

950

Width (mm)

900

1000

1100

1200

HEAVY DUTY

DITCH CLEANING WITH TEETH OR BLADE SAE capacity (l)

590

720

820

1010

Width (mm)

2000

2000

1800

1800

TRAPEZOID Width (mm)

11-4

350-2750

SECTION 11 - SPECIFICATIONS MACHINE OVERALL DIMENSIONS (CX160B) (monobloc boom)

CS00K520A

1 Dippers 2.20 m 2.60 m 3.00 m (A).................................................................................................... 3.00 m ................ 2.96 m ................. 3.13 m (B).................................................................................................... 2.93 m ................ 2.93 m ................. 2.93 m (C).................................................................................................... 8.49 m ................ 8.44 m ................. 8.52 m (D).................................................................................................... 4.40 m ................ 4.40 m ................. 4.40 m (E).................................................................................................... 2.54 m ................ 2.54 m ................. 2.54 m (F) .................................................................................................... 1.02 m ................ 1.02 m ................. 1.02 m (G) ................................................................................................... 2.41 m ................ 2.41 m ................. 2.41 m (H).................................................................................................... 3.99 m ................ 3.99 m ................. 3.99 m (I) ..................................................................................................... 3.19 m ................ 3.19 m ................. 3.19 m (J) .................................................................................................... 1.99 m ................ 1.99 m ................. 1.99 m (K) (standard track pads) ................................................................. 0.60 m ............... 0.60 m ................. 0.60 m (L) (with 500 mm track pads) ........................................................... 2.49 m ................ 2.49 m ................. 2.49 m (L) (with 600 mm track pads) ........................................................... 2.59 m ................ 2.59 m ................. 2.59 m (L) (with 700 mm track pads) ........................................................... 2.69 m ................ 2.69 m ................. 2.69 m (M) ................................................................................................... 0.44 m ................ 0.44 m ................. 0.44 m (N).................................................................................................... 2.95 m ................ 2.95 m ................. 2.95 m

11-5

SECTION 11 - SPECIFICATIONS (CX160B) (articulated boom)

CT04E003A

2 Dippers 2.20 m 2.60 m 3.00 m (A) ....................................................................................................2.77 m ................2.79 m .................3.03 m (B) ....................................................................................................2.93 m ................2.93 m .................2.93 m (C) ....................................................................................................8.37 m ................8.33 m .................8.36 m (D) ....................................................................................................4.40 m ................4.40 m .................4.40 m (E) ....................................................................................................2.54 m ................2.54 m .................2.54 m (F) ....................................................................................................1.02 m ................1.02 m .................1.02 m (G)....................................................................................................2.41 m ................2.41 m .................2.41 m (H) ....................................................................................................3.99 m ................3.99 m .................3.99 m (I)......................................................................................................3.19 m ................3.19 m .................3.19 m (J).....................................................................................................1.99 m ................1.99 m .................1.99 m (K) (standard track pads) .................................................................0.60 m ............... 0.60 m .................0.60 m (L) (with 500 mm track pads) ...........................................................2.49 m ................2.49 m .................2.49 m (L) (with 600 mm track pads) ...........................................................2.59 m ................2.59 m .................2.59 m (L) (with 700 mm track pads) ...........................................................2.69 m ................2.69 m .................2.69 m (M)....................................................................................................0.44 m ................0.44 m .................0.44 m (N) ....................................................................................................2.95 m ................2.95 m .................2.95 m

11-6

SECTION 11 - SPECIFICATIONS (CX180B) (monobloc boom)

CS00K520A

3 Dippers 2.20 m 2.60 m 3.00 m (A).................................................................................................... 3.00 m ................ 2.96 m ................. 3.12 m (B).................................................................................................... 2.94 m ................ 2.94 m ................. 2.94 m (C).................................................................................................... 8.49 m ................ 8.44 m ................. 8.52 m (D).................................................................................................... 4.50 m ................ 4.50 m ................. 4.50 m (E).................................................................................................... 2.54 m ................ 2.54 m ................. 2.54 m (F) .................................................................................................... 1.04 m ................ 1.04 m ................. 1.04 m (G) ................................................................................................... 2.41 m ................ 2.41 m ................. 2.41 m (H).................................................................................................... 4.18 m ................ 4.18 m ................. 4.18 m (I) ..................................................................................................... 3.37 m ................ 3.37 m ................. 3.37 m (J) .................................................................................................... 2.20 m ................ 2.20 m ................. 2.20 m (K) (standard track pads) ................................................................. 0.60 m ............... 0.60 m ................. 0.60 m (L) (with 600 mm track pads) ........................................................... 2.80 m ................ 2.80 m ................. 2.80 m (L) (with 700 mm track pads) ........................................................... 2.90 m ................ 2.90 m ................. 2.90 m (L) (with 800 mm track pads) ........................................................... 3.00 m ................ 3.00 m ................. 3.00 m (M) ................................................................................................... 0.46 m ................ 0.46 m ................. 0.46 m (N).................................................................................................... 2.96 m ................ 2.96 m ................. 2.96 m

11-7

SECTION 11 - SPECIFICATIONS WORKING RANGE (CX160B) (monobloc boom)

CS00K521

4 Dippers 2.20 m 2.60 m 3.00 m (A) (Maximum digging reach) ............................................................8.67 m ................9.04 m .................9.38 m (B) (Maximum digging reach at ground level) .....................................8.50 m ................8.87 m .................9.22 m (C) (Maximum digging depth) ............................................................5.66 m ................6.06 m .................6.49 m (D) (Maximum digging depth over a length of 2.44 m) ........................5.43 m ................5.85 m .................6.29 m (E) (Maximum dump height)..............................................................6.38 m ................6.61 m .................6.69 m (F) (Maximum working height)...........................................................9.01 m ................9.24 m .................9.29 m (G) (Minimum attachment swing radius) ............................................2.98 m ................2.99 m .................2.98 m (H) (Maximum digging depth on a vertical face) .................................4.72 m ................5.08 m .................5.22 m (I) (Maximum length of flat-bottomed trench).....................................2.44 m ................2.44 m .................2.44 m

11-8

SECTION 11 - SPECIFICATIONS (CX160B) (articulated boom)

CT04E004A

5 Dippers 2.20 m 2.60 m 3.00 m (A) (Maximum digging reach)............................................................ 8.57 m ................ 8.95 m ................. 9.31 m (B) (Maximum digging reach at ground level)..................................... 8.39 m ................ 8.78 m ................. 9.14 m (C) (Maximum digging depth)............................................................ 5.24 m ................ 5.62 m ................. 6.03 m (D) (Maximum digging depth over a length of 2.44 m)........................ 5.11 m ................ 5.51 m ................. 5.92 m (E) (Maximum dump height) ............................................................. 7.22 m ................ 7.66 m ................. 7.79 m (F) (Maximum working height) .......................................................... 9.91 m .............. 10.25 m ............... 10.49 m (G) (Minimum attachment swing radius) ............................................ 2.16 m ................ 2.08 m ................. 2.16 m (H) (Maximum digging depth on a vertical face)................................. 4.26 m ................ 4.17 m ................. 4.56 m (I) (Maximum length of flat-bottomed trench) .................................... 2.44 m ................ 2.44 m ................. 2.44 m

11-9

SECTION 11 - SPECIFICATIONS (CX180B) (monobloc boom)

CS00K521

6 Dippers 2.20 m 2.60 m 3.00 m (A) (Maximum digging reach) ............................................................8.67 m ................9.04 m .................9.38 m (B) (Maximum digging reach at ground level) .....................................8.49 m ................8.87 m .................9.21 m (C) (Maximum digging depth) ............................................................5.65 m ................6.04 m .................6.47 m (D) (Maximum digging depth over a length of 2.44 m) ........................5.42 m ................5.84 m .................6.28 m (E) (Maximum dump height)..............................................................6.40 m ................6.62 m .................6.71 m (F) (Maximum working height)...........................................................9.02 m ................9.25 m .................9.30 m (G) (Minimum attachment swing radius) ............................................2.98 m ................2.99 m .................2.98 m (H) (Maximum digging depth on a vertical face) .................................4.70 m ................5.07 m .................5.21 m (I) (Maximum length of flat-bottomed trench).....................................2.44 m ................2.44 m .................2.44 m

11-10

SECTION 11 - SPECIFICATIONS HYDRAULIC BREAKERS (optional) Model....................................................................................................................................................... CB 150 Weight of standard breaker (with standard 46 kg tool) ............................................................................. 830 kg Weight of "S" type breaker (with standard 46 kg tool) .............................................................................. 820 kg Impact rate..................................................................................................................... 500 - 1000 Impacts/min Operating pressure.........................................................................................................................125 - 150 bar Min. relief valve setting ...................................................................................................................175 - 200 bar Max. relief valve setting ...........................................................................................................................220 bar Flow ............................................................................................................................................... 60 - 120 l/min Power............................................................................................................................................ 30 kW (41 hp) Fluid temperature .............................................................................................................................+40 - +60°C Maximum permitted fluid temperature ...............................................................................................-20 - +80°C Noise level measured + 4 dB guaranteed by the manufacturer.

In accordance with European directive 2000/14/EC, LwA: standard type ......................................................................................................................... 136 decibels "S" type ................................................................................................................................... 126 decibels

Tools

CS99C631

7 Type Length (mm) Weight (kg) Diameter (mm) A = Chisel .......................................................................... 900............................. 46 ................................. Ø 95 A = Long chisel ................................................................. 1050............................ 55 ................................. Ø 95 B = Moil point..................................................................... 900............................. 43 ................................. Ø 95 B = Long moil point........................................................... 1050............................ 53 ................................. Ø 95 C = Blunt tool ..................................................................... 800............................. 39 ................................. Ø 95 D = Compaction plate ........................................................ 800............................. 95 ............................... Ø 350 E = Parallel asphalt shovel ................................................ 900............................. 87 ..........................width 200 E = Transverse asphalt shovel........................................... 900............................. 87 ..........................width 200

11-11

SECTION 11 - SPECIFICATIONS Model .................................................................................................................................................... CB 200S Weight (with standard 67 kg tool) ........................................................................................................... 1040 kg Impact rate ....................................................................................................................... 400 - 800 Impacts/min Operating pressure ........................................................................................................................ 135 - 145 bar Min. relief valve setting............................................................................................................................ 185 bar Max. relief valve setting........................................................................................................................... 220 bar Flow ............................................................................................................................................... 80 - 130 l/min Power ............................................................................................................................................ 31 kW (42 hp) Fluid temperature............................................................................................................................. +40 - +60°C Maximum permitted fluid temperature .............................................................................................. -20 - +80°C Noise level measured + 4 dB guaranteed by the manufacturer.

In accordance with European directive 2000/14/EC, LwA ............................................................ 124 decibels

Tools

CS99C632

8 Type Length (mm) Weight (kg) Diameter (mm) A = Chisel ......................................................................... 1000 ............................68 ............................... Ø 115 B = Moil point .................................................................... 1000 ............................68 ............................... Ø 115 C = Blunt tool ..................................................................... 800 .............................58 ............................... Ø 115 D = Pyramid point ............................................................. 1000 ............................67 ............................... Ø 115

11-12

SECTION 11 - SPECIFICATIONS OVERALL DIMENSIONS CB 150 model

CT04K023

9 CB 150S model

CT04K024

10 NOTE: These values are given in millimeters.

11-13

SECTION 11 - SPECIFICATIONS CB 200S model

CT04K025

11 NOTE: These values are given in millimeters.

11-14

SECTION 11 - SPECIFICATIONS QUICK COUPLER (optional) DIMENSIONS NEEDED TO FIT THE QUICK COUPLER Bucket pin diameter

80 mm

Width between lugs

277 mm

Minimum distance between bucket centres

401.5 mm

Maximum distance between bucket centres

451.5 mm

!

!

WARNING

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 CASE Dealer.

WEIGHT 297 kg OVERALL DIMENSIONS

C

B

A CS00J503

12 A ............................................................................................................................................................. 942 mm B ............................................................................................................................................................. 522 mm C ............................................................................................................................................................. 442 mm

11-15

SECTION 11 - SPECIFICATIONS

NOTES

11-16

SECTION 12 ALPHABETICAL INDEX A

C

Accessories icons .............................................. 4-13 Adjustment and locking the option pedals........... 4-23 Adjustment of engine valve rocker clearances ...... 8-7 Air conditioning .................................................. 8-23 Air filter .............................................................. 7-44 Air vents .............................................................. 4-6 Alternator............................................................. 9-7 Anti-freeze/Anti-corrosion..................................... 7-4 Anti-theft device ................................................... 5-4 Anti-theft protection indicator .............................. 4-12 Arm angle adjustment lever........................... 4-4, 4-7 Articulated boom adjustment (CX160B) ......................................................... 4-21 Articulated boom or hydraulic breaker or high flow control........................................... 4-5 Ashtray................................................................ 4-7 Automatic engine idle speed selector ................. 4-11 Auxiliary 12 volts socket ....................................... 4-9 Auxiliary hydraulic circuit flow patterns................ 5-37 Auxiliary hydraulic circuits .................................. 5-32

Connecting booster batteries ................................ 9-6 Controls/Instruments/Accessories......................... 4-1 Cooling system .................................................. 7-25 Cup holder ......................................................... 4-28

B Backhoe buckets ............................................... 11-4 Batteries .............................................................. 9-3 Before using the hydraulic breaker ....................... 3-6 Before using the machine.............................. 3-2, 5-1 Boom and bucket right-hand control lever........... 4-20 Booms............................................................... 11-4 Bringing the machine up to operating temperature............................. 5-9 C Cab ................................................................... 11-3 Cab door ............................................................. 4-1 Cab door sliding windows................................... 4-27 Cab light ............................................................ 4-24 Cab protection (F.O.P.S.).............................. 3-4, 8-8 Cab radio compartment........................................ 4-5 Car radio mute control.......................................... 4-7 Checking for cylinder leakage ............................ 8-10 Checking the quick coupler latching hook opening.................................... 8-21 Choice of tools on a hydraulic breaker ................ 5-45 Cigarette lighter ................................................... 4-6 Clock ................................................................... 4-6 Coat hanger hook .............................................. 4-24

D Daily inspections .................................................. 6-2 Decals ............................................................... 3-10 Description of the main components ..................... 2-3 Dipper and upperstructure swing left-hand control lever..................................... 4-20 Dippers .............................................................. 11-4 E Electrical system .................................................. 9-1 Emergency shut down switch ............................... 4-8 Engine ......................................................7-22, 11-1 Engine acceleration button and working mode selector ..................................... 4-4 Engine coolant temperature indicator.................. 4-12 Engine hood ...................................................... 4-38 Engine idle speed selector.................................... 4-4 Engine oil............................................................. 7-2 Engine operation................................................ 5-10 Engine troubleshooting....................................... 8-27 Environment ........................................................ 7-4 Error code indicator ............................................ 4-12 F Fan and alternator drive belt ................................. 8-6 Fire extinguisher................................................... 8-8 Fluid and lubricant capacities and specifications ............................................ 7-4 Fluids and lubricants ............................................ 7-1 Footrest ............................................................. 4-24 Front RH console ................................................. 4-6 Front storage box............................................... 4-36 Fuel ..................................................................... 7-3 Fuel level indicator ............................................. 4-12 Fuel system ....................................................... 7-28 Fuel tank............................................................ 4-35 Fuel tank filling pump ......................................... 4-43 Fuel tank filter ...................................................... 8-7 Function and message display screen .......4-10, 4-12 Function cancellation lever and lifting the control arm ................................. 4-7

12-1

SECTION 12 - ALPHABETICAL INDEX F

M

Function cancellation lever and safety bar........... 4-19 Fuse box............................................................ 4-25 Fuses................................................................... 9-1

Machine operation ............................................. 5-14 Machine overall dimensions ............................... 11-5 Machine travel ................................................... 5-15 Magazine rack ................................................... 4-27 Maintenance and adjustments.............................. 3-7 Maintenance/Adjustments .................................... 8-1 Message display ................................................ 4-13

G Grease points ...................................................... 7-5 Greasing the hydraulic breaker ........................... 7-17 Greasing the swing reduction gear...................... 7-19 Greasing the turntable teeth ............................... 7-18

N Noise levels ....................................................... 11-3

H Hand signals ...................................................... 3-22 Handling the hydraulic breaker ........................... 5-44 Handling the load with the quick coupler ............. 5-20 Handling the machine......................................... 5-18 Hardware torque inspection................................ 8-29 Heating and ventilation or air-conditioning controls ............................. 4-15 Horn .................................................................... 4-7 Horn volume control ........................................... 4-10 Hourmeter...................................................4-11, 6-2 Hydraulic breaker breaking principles ................. 5-44 Hydraulic breaker or high flow hydraulic circuits.............................. 5-33 Hydraulic breaker servicing instructions ................ 6-5 Hydraulic breakers ........................................... 11-11 Hydraulic fluid ...................................................... 7-1 Hydraulic fluid temperature indicator ................... 4-12 Hydraulic system.......................................7-35, 11-1 I Identification numbers/Machine components......... 2-1 Inspecting and cleaning the machine .................... 8-9 Intervals ............................................................... 6-6 L Left-hand control arm ........................................... 4-7 Levels ................................................................ 7-20 Load handling .................................................... 5-19 Load handling eyes ............................................ 4-40 Load handling limits charts ................................. 5-21 Low flow hydraulic circuit control pedal ............... 4-22 Lower front window ............................................ 4-34 Lower panels ..................................................... 4-38 Lowering the attachment in the event of a machine failure......................... 5-31 Lubrication/Filters/Fluids....................................... 7-1

12-2

O Official documents................................................ 1-2 Offset-backhoe boom or high flow hydraulic circuit control pedal ......................... 4-22 Offset-backhoe boom or hydraulic breaker or high flow control........................................... 4-5 Oil range.............................................................. 7-2 Operating icons.................................................. 4-13 Operating instructions .......................................... 5-1 Operating the backhoe bucket............................ 5-22 Operating the machine ..................................3-3, 5-2 Operating the machine in cold weather............... 5-12 Operating the machine in hot weather ................ 5-13 Operating the machine in water .......................... 5-21 Operating the machine on sloping ground........... 5-22 Operator's seat .................................................. 4-29 Operator’s compartment..................................... 11-3 Option control ........................................4-5, 4-7, 4-9 Option pedals..................................................... 4-21 Optional tool supply valves ................................. 4-42 Overload indicator switch ..................................... 4-5 P Parking the machine ...................................3-5, 5-28 Plastic and resin parts ........................................ 8-10 Position of the operator’s compartment controls and accessories.................................. 4-3 Preventing fires or explosions............................... 3-8 Preventing risks caused by vibrations ................... 3-4 Prevention of burns .............................................. 3-9 Q Quick coupler............................................3-4, 11-15 Quick coupler incorrect functioning ....................... 6-4 Quick coupler installation.................................... 5-23 Quick coupler locking and unlocking control switch ..........................4-8, 4-26

SECTION 12 - ALPHABETICAL INDEX Q

S

Quick coupler servicing instructions...................... 6-4 Quick coupler tool lubrication.............................. 7-16 Quick tool installation and removal ..................... 5-23

Storing the machine ........................................... 10-1 Sun shield.......................................................... 4-27 Swing reduction gear.......................................... 7-48 Systems display and function control panel ..............................4-9, 4-10

R Radiators and oil coolers...................................... 8-5 Rear view mirrors............................................... 4-36 Rear window (emergency exit) ........................... 4-34 Refrigerated compartment.................................. 4-27 Releasing pressure in the hydraulic system ........ 7-33 Replacing a backhoe bucket .............................. 8-12 Replacing a bulb .................................................. 9-8 Replacing a hydraulic breaker ............................ 8-20 Replacing a tool bushing on a hydraulic breaker . 8-17 Replacing a tool on a hydraulic breaker .............. 8-15 Replacing a tooth on the backhoe bucket ........... 8-11 RH console.......................................................... 4-9 Right, left, front and rear of the machine ............... 1-3 Right-hand control arm......................................... 4-4 Roof curtain ....................................................... 4-26 Roof hatch......................................................... 4-26 Rotary light cable ............................................... 4-39 Rotary light control ............................................... 4-4 Run-in period ....................................................... 5-3 S Safety area .......................................................... 3-5 Safety bar............................................................ 4-7 Safety devices ................................................... 11-2 Safety instructions................................................ 3-1 Safety valves ..................................................... 4-42 Safety/Decals/Hand signals ................................. 3-1 Servicing instructions ........................................... 6-1 Servicing intervals................................................ 6-1 Shimming the backhoe bucket ........................... 8-14 Side doors ......................................................... 4-37 Special conditions of use of the hydraulic breaker ................................. 5-45 Specifications .................................................... 11-1 Starter motor........................................................ 9-7 Starter switch....................................................... 4-4 Starting the engine............................................... 5-7 Steps and access handles ................................... 4-2 Stopping the engine ........................................... 5-11 Storage ............................................................. 10-1 Storage compartment ........................................ 4-28 Storage tray.................................................. 4-6, 4-9

T Teeth and tooth tip wear limits ............................ 8-11 Temperature probe .............................................. 4-6 Tightening torque of the track pad screws............. 8-4 To the owner........................................................ 1-1 Towing holes...................................................... 4-41 Towing the machine ........................................... 5-30 Track rollers and idler wheels ............................... 8-4 Tracks.................................................................. 8-1 Transmission component oil ................................. 7-1 Transporting the machine................................... 5-39 Travel control levers and pedals ......................... 4-21 Travel reduction gears........................................ 7-50 Travel speed selector ......................................... 4-10 Trip control......................................................... 4-11 Type, serial number and year of manufacture of the machine ................. 2-1 U Undercarriage .................................................... 11-2 Using the hydraulic breaker .................................. 3-6 V Vibration level inside the cab .............................. 11-3 W Wear limits on a hydraulic breaker ...................... 8-18 Weights ............................................................. 11-4 Welding on the machine....................................... 8-9 Windshield ......................................................... 4-33 Windshield washer reservoir............................... 4-39 Windshield washer switch .................................. 4-11 Windshield wiper switch ..................................... 4-11 Working lights switch.......................................... 4-11 Working mode indicator...................................... 4-12 Working range ................................................... 11-8

12-3

SECTION 12 - ALPHABETICAL INDEX

NOTE: CNH France S.A. Company reserves the right to make changes in the specification and design of the machine without prior notice and without incurring any obligation to modify units previously sold.

The description of the models shown in this manual has been made in accordance with the technical specifications known as of the date of design of this document.

12-4

CASE TECHNICAL MANUALS You can obtain manuals on the operation, maintenance and repair of your machine from your CASE Dealer. To ensure quick and efficient service, consult your CASE Dealer for assistance in ordering the correct manuals for your machine.

Your CASE Dealer can deal with orders for operator’s manuals, parts catalogues and service manuals.

Always give the type and serial number of your machine so that your CASE Dealer can supply you with the right manuals for your machine.

Printed in France

OM A4 Jaune Gabarit MM.qxd

31/10/2007

11:28

Page 1

CX160B and CX180B Hydraulic crawler excavators

Operator's Manual Lep 87600995 EN Replaces Lep 87624644 EN