Case CX160B Tier 3 Crawler Excavator Operator's Manual 84538869 - PDF DOWNLOAD

CX160B Tier 3 Crawler Excavator

OPERATOR’S MANUAL

Part number 84538869 2nd edition English September 2011 Replaces part number 87364354NA

CX160B HYDRAULIC EXCAVATOR OPERATOR’S MANUAL

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

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

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

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

THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF DEATH OR SERIOUS INJURY M171D

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

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

●

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

●

CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. The color associated with Caution is YELLOW.

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

The first panel indicates the nature of the hazard.

●

The second panel indicates the appropriate avoidance of the hazard.

●

Background color is YELLOW

●

Prohibition symbols such as

and

STOP

if used, are RED.

IMPROPER OPERATION OF THIS MACHINE CAN CAUSE DEATH OR SERIOUS INJURY. BEFORE USING THIS MACHINE, MAKE CERTAIN THAT EVERY OPERATOR: ●

Is instructed in safe and proper use of the machine.

●

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

●

Reads and understands ALL Safety Decals on the machine.

●

Clears the area of other persons.

●

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

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

WARNING_01_NA

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

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

Wash hands after handling.

Copyright © 2011 CNH America LLC All Rights Reserved

TABLE OF CONTENTS CHAPTER 1 GENERAL INFORMATION To The Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Identification Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 CHAPTER 2 SAFETY AND DECALS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Utility Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Safety Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Starting and Stopping Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Seat Belt Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 CHAPTER 3 INSTRUMENTS AND CONTROLS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Cab Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Steps and Access Handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Operator’s Compartment Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Operator’s Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Function Cancellation Lever and Safety Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Anti-theft Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Automatic Temperature Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Travel Control Levers and Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 Cab Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 Machine Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 CHAPTER 4 OPERATING INSTRUCTIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Run-in Period of a New Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Before Operating the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Checking Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Machine Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Transporting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Machine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 CHAPTER 5 LUBRICATION, FILTERS, AND FLUIDS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 General Safety Before You Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Lubrication and Maintenance Quick Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

I

CHAPTER 6 MAINTENANCE AND ADJUSTMENTS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Replacing a Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Cab Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Hardware Torque Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 CHAPTER 7 ELECTRICAL Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 CHAPTER 8 SPECIFICATIONS Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Operator’s Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Monobloc Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Lifting Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 CHAPTER 9 INDEX

II

CHAPTER 1 - GENERAL INFORMATION

Chapter 1 GENERAL INFORMATION TO THE OWNER

CT07A059

Figure 1

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

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

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

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

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

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

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

1-1

CHAPTER 1 - GENERAL INFORMATION The machine must undergo regular inspections, the frequency of which varies according to the type of use. Consult your CASE Dealer.

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

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

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

• All persons who will be operating this machine shall possess a valid local vehicle operating permit and/or other applicable local age work permits.

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 additional manuals, or manuals in another language, consult your CASE Dealer.

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.

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

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

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

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

1-2

CHAPTER 1 - GENERAL INFORMATION R I G H T, L E F T, F RO N T, A N D R E A R O F T H E MACHINE

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

The terms “Right”, “Left”, “Front” and “Rear” are used in this manual to indicate the sides as they are seen from the operator’s seat when the cab is over the idler.

6

1

4

6

3

5

5

2 Figure 2

CS99A820

1. FRONT 2. REAR

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

5. TRAVEL REDUCTION GEARS 6. IDLER

1-3

CHAPTER 1 - GENERAL INFORMATION

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

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

Machine ➤ Machine Model and Type

➤ Product Identification Number: P.I.N.

➤ Year of Build

Component Serial Numbers ➤ Engine Serial Number

➤ Transmission and Serial Number

➤ ROPS Cab or Canopy Serial Number

➤ Attachment Serial Number

➤

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

1-4

Figure 3

CHAPTER 1 - GENERAL INFORMATION

MACHINE COMPONENTS

Figure 4

BS07A128

1. Bucket

9. Cab

17. Turn table bearing

2. Bucket link

10. Swing unit

18. Track shoe

3. Arm link

11. Fuel tank

19. Travel unit

4. Bucket cylinder

12. Hydraulic oil tank

20. Lower roller

5. Arm

13. Air cleaner

21. Upper roller

6. Arm cylinder

14. Battery

22. Track tension unit

7. Boom

15. Engine and radiator

23. Take up roller

8. Boom cylinder

16. Counterweight 1-5

CHAPTER 1 - GENERAL INFORMATION

NOTES

1-6

CHAPTER 2 - SAFETY AND DECALS

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

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

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

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

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

STARTING AND STOPPING PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Fuel Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Burn Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Hazardous Chemical Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Transporting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Parking The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Ductile Iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 SEAT BELT PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Cab Interior Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Exterior Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

2-1

CHAPTER 2 - SAFETY AND DECALS

NOTES

2-2

CHAPTER 2 - SAFETY AND DECALS

SAFETY RULES WARNING WARNING: This safety alert symbol indicates important safety messages in this manual. When you see this symbol, carefully read the message that follows and be alert to the possibility of death or serious injury.

M171C

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

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

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

CT06M020

Figure 1

OPERATOR’S MANUAL LOCATION AND STORAGE

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

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

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

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

2-3

CHAPTER 2 - SAFETY AND DECALS

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

.

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

• • • •

Electrical Power Line Gas Line Water Line Communication Line - Telephone or Cable Television

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

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

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

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

RH99G001

Figure 2

CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU PERFORM ANY MACHINE OPERATION

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

2-4

CHAPTER 2 - SAFETY AND DECALS

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

• • • •

The first panel indicates the nature of the hazard.

The second panel indicates the appropriate avoidance of the hazard.

Background color is YELLOW. Prohibition symbols such as

and

STOP

if used are RED.

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

1

2 CS97M019

Figure 3

1. WORKING AREA 2. SAFETY AREA

2-5

CHAPTER 2 - SAFETY AND DECALS

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

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

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

PERSONAL SAFETY

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

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

• Know and use the protective equipment that is to

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

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

• Before you drive or operate in an area with high

• Certain protective equipment should be replaced

• Contact with high voltage lines, underground

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

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

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

• Inspect the seat belt mounting bolts on a daily basis to ensure their integrity.

• Operate the machine controls from the operator’s seat only. Always fasten the seat belt and keep it securely fastened when operating the machine.

• If this machine rolls over, you can be injured or killed. You must make a judgment if weather, road, or earth conditions will permit safe operation on a hill, ramp, or rough ground.

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

• Be alert and always know the location of all workers in your area. Keep all other persons completely away from your machine. Injury or death can result if you do not follow these instructions.

2-6

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

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

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

who

has

the

GENERAL

• It is the responsibility of the operator to read and understand the Operator’s Manual and other information provided and use the correct operating procedure. Machines should be operated only by qualified operators.

• Do not operate this machine or perform maintenance work if you have not had appropriate training. Make certain you have read and fully understand the instructions and warnings in this manual.

• Do not permit riders on the machine.

• Make sure that all protective guards, canopies, doors, etc. are in place and secure.

• Remove all loose objects stored in the machine.

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

• Do not use the machine as a manlift.

CHAPTER 2 - SAFETY AND DECALS PROPER ENTRY AND EXIT

• Use the recommended hand holds and steps with at least three points of support when getting on and off the machine. Keep steps and platform clean.

• Do not jump off the machine.

• Do not dismount while the machine is in motion.

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

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

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

OPERATING PRECAUTIONS

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

• If a failure that causes loss of control such as

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

Sound the horn before starting.

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

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

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

• Understand the machine limitations and keep the

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

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

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

• Start and operate the machine only from the

machine under control.

• Operate and drive the machine with care and at speed compatible with conditions. Use extra caution when operating over rough ground, on slopes, and when turning.

• Note and avoid all hazards and obstructions such as ditches, underground lines, trees, cliffs, overhead electrical wires or areas where there is danger of a slide.

• Carry loads in recommended positions for maximum stability.

• Do not bypass the machine’s interlock system.

• Never lift loads in excess of capacity.

• Use the recommended machine ballast and

The interlock system must be repaired if it malfunctions.

• Know and understand the job site traffic flow

• Use jumper cables only in the recommended

patterns, and obey signalmen, road signs and flagmen.

operator’s station.

manner. Improper use can result in battery explosion or unexpected machine motion.

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

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

• Park the machine on level ground whenever possible and apply the parking brake. On grades, park the machine with the track securely blocked.

• Before leaving the operator’s station, lower the

counterweighting.

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

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

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

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

2-7

CHAPTER 2 - SAFETY AND DECALS

• Use proper transport devices when roading the

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

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

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

• Stay away from hazardous areas such as ditches,

• Use the approved attachment point when using

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

the machine for towing. If a cable or chain is used, keep people away from the tow line.

• Be alert and always know the location of all

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

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

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

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

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

• Contact

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

• Before you drive or operate in an area with high voltage lines, cables, or a power station, tell the power or utility company what you are going to do.

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

If a part of the machine touches high voltage power: 1. Warn other workers NOT TO TOUCH THE MACHINE and to stay away from the machine.

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

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

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

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

2-8

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

• Develop fluid and smooth operating techniques and maintain the surface condition where the machine travels in order to control vibration transfer to the operator.

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

CHAPTER 2 - SAFETY AND DECALS MAINTENANCE PRECAUTIONS

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

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

• Wear protective glasses and other required safety equipment when servicing or repairing the machine.

• Wear gloves to protect hands when handling cable.

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

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

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

• To prevent unexpected movement, securely block working elements when repairing or changing working tool parts such as cutting edges.

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

• Whenever servicing or replacing hardened pins, etc., use a brass drift or other suitable material between the hammer and pin. Alternative: Use a brass hammer, drift or suitable material on the pin, etc.

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

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

FUEL HANDLING PRECAUTIONS

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

• Never remove the fuel cap or refuel gasoline engine powered machines with the engine running or hot. Never allow fuel to spill on hot machine components. Never allow fuel to spill on the environment.

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

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

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

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

• Never use fuel for cleaning purposes.

• Use the correct fuel grade for the operating season.

• Use extreme caution when removing radiator caps, drain plugs, grease fittings or pressure taps.

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

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

• Use a piece of cardboard, newspaper, or wood to check for pressurized leaks to prevent fluid penetrating the skin. Pressurize accumulators with the proper gas according to manufacturer’s recommendations.

• Towing this machine is not recommended.

• Observe the proper maintenance procedures.

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CHAPTER 2 - SAFETY AND DECALS

• Before you service this machine and before you

BURN PREVENTION

WARNING Battery acid causes burns. Batteries contain sulfuric acid. Battery electrolyte contains sulfuric acid.

Contact with skin and eyes could result in severe irritation and burns. Always wear splash-proof goggles and protective clothing (gloves and aprons).

Wash hands after handling. Failure to comply could result in death or serious injury.

WC120A

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

TRANSPORTING PRECAUTIONS

• Know the rules, laws, and safety equipment that may be necessary for transporting this machine on a road or highway.

FIRE EXTINGUISHER

CAUTION Burn hazard Hot coolant can spray out if you remove the filler cap while the system is hot. After the system has cooled, turn the filler cap to the first notch and wait for all pressure to release before proceeding. Failure to comply could result in minor or moderate injury.

C0433A

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

• Hot coolant can spray out if the radiator cap is removed. To remove the radiator cap, let the cooling system cool, turn to the first notch, wait until the pressure is released, then remove the radiator cap.

HAZARDOUS CHEMICAL PRECAUTIONS

• If you are exposed to or come in contact with hazardous chemicals you can be seriously injured. The fluids, lubricants, paints, adhesives, coolants, etc. used with your machine can be hazardous.

• Material Safety Data Sheets (MSDS) provide information about the chemical substances within a product, safe handling procedures, first aid measures and procedures to be taken when the product is accidentally spilled or released. MSDS information is available from your dealer.

• Before you service the machine, check the MSDS for each fluid, lubricant, etc., used in your machine. This information indicates what the risks are and how to service the machine safely. Follow this information when servicing the machine.

2-10

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

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

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

2. Lower the attached equipment to the ground.

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

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

This decreases the temperature of the engine parts evenly.

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

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

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

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

This will prevent the tracks from freezing to the ground.

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

DUCTILE IRON

• Before you weld, cut or drill holes in a part on this machine, make sure the part is not cast ductile iron. See your dealer if you do not know if a part is cast ductile iron.

CHAPTER 2 - SAFETY AND DECALS

SEAT BELT PRECAUTIONS

2

1

3

Figure 4

BD02M045

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

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

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

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

4. The seat belt will automatically retract.

WARNING Roll over hazard. Securely fasten the seat belt. Your machine is equipped with an optional Roll over protective structure (ROPS) cab, ROPS canopy, or FOPS frame for your protection. The seat belt can help ensure your safety if it is properly used and maintained. Never wear a seat belt loosely or with slack in the belt system. Failure to comply could result in death or serious injury.

WO143A

2-11

CHAPTER 2 - SAFETY AND DECALS

SAFETY DECALS WARNING Injury or death can result if you cannot read a safety decal or if a safety decal is missing. Replace any missing or damaged safety decals and keep all safety decals clean. See your dealer for new safety decals. Failure to comply could result in death or serious injury.

SC002

Make sure that you read all the safety decals and all instructional decals. Check these decals every day before you start. Clean these decals if you cannot read the words.

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

You must replace a decal if the decal is damaged, missing, or cannot be read. If a decal is on a part that is replaced, make sure the decal is on the new part.

See your dealer for new decals.

KHP1525

2-12

Figure 5

CHAPTER 2 - SAFETY AND DECALS CAB INTERIOR DECALS

BS06B814

Figure 6

2-13

CHAPTER 2 - SAFETY AND DECALS

1

Figure 7

WARNING

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

• • • • •

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

3

2

KHP11600

Figure 8

KHP12170

Figure 9

Decal number KHP11600-00

Decal number KHP12170-00

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

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

2-14

CHAPTER 2 - SAFETY AND DECALS

4

BS06N810

5

Figure 10

The decal indicates the voltage rating of the lighter socket. Do not use equipment of any other voltage.

The decal is located on the right front console.

KHP12300

Figure 11

Decal number KHP11380-00 The control pattern decal indicates the pattern of the controller. Make certain the actual pattern and the decal in the machine match.

6

KHP12300

Figure 12

Decal number KHP1587-00 This decal indicates the machine is equipped with a control pattern selector and is located on the inside of the right cab window.

2-15

CHAPTER 2 - SAFETY AND DECALS EXTERIOR DECALS

BS07A129

2-16

Figure 13

CHAPTER 2 - SAFETY AND DECALS

7

KHP1014

8

Figure 14

RAP0144

Figure 15

Decal number KHP1014-00

Decal number KHP0144-00

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

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

2-17

CHAPTER 2 - SAFETY AND DECALS

9

KHP1536

11

Figure 16

Figure 18

KHP1533

Decal number KHP1536-00

Decal number KHP1533-00

Located in the battery compar tment, this decal advises use of safe battery procedures and explosive danger.

Inside the engine compartment, this decal warns of the hazard associated with rotating par ts and components.

10

KHP0210

12

Figure 17

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

KHP1534

Figure 19

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

2-18

CHAPTER 2 - SAFETY AND DECALS

13

KHP1542

15

Figure 20

KPH1535

Figure 22

Decal number KHP1542-00

Decal number KHP1535-00

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

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

16 14

KPH1011

Figure 23

Decal number KHP1011-00 KPH11681

Figure 21

Decal number KHP11681-00

This decal warns the operator of slippery surfaces.

This decal instructs the operator to use recommended diesel fuel only.

2-19

CHAPTER 2 - SAFETY AND DECALS

17

KPH1010

19

Figure 24

Decal number KHP1010-00 Instructs operator to lock engine hood in place when opening.

KPH10713

Figure 26

Decal number KHP1013-00 This decal cautions against starting the machine from anywhere other than the operator’s seat to prevent unexpected articulation.

18

20

KPH12210

Figure 25

Decal number KHP12210-00 This decal warns against standing or climbing on the rear of the machine.

KPH0700

Figure 27

Decal number KHP0700-00 This decal states the importance of using correct booster/jumper battery procedures.

2-20

CHAPTER 2 - SAFETY AND DECALS HAND SIGNALS When operating the machine, never attempt to carry out tasks calling for fine control or to work in areas where visibility is poor or impaired without seeking the assistance of a signalman. Make perfectly sure that you and the signalman understand the signals to be used.

Figure 28

BI97D059

START THE ENGINE

STOP THE ENGINE

Figure 29

BP97D022

COME TO ME

Wave hands back and forth (palms inward).

Figure 30

BI97D025

BP97D023

FIGURE 31

MOVE AWAY FROM ME

Wave hands back and forth (palms outward).

2-21

CHAPTER 2 - SAFETY AND DECALS

Figure 32

BP97D030

GO THIS FAR

ALL STOP AND HOLD

Figure 33

BI97D029

BI97D021

STOP

Move both hands back and forth.

FIGURE 34

RAISE LOAD OR TOOL

2-22

FIGURE 36

EMERGENCY STOP

Move one hand back and forth.

BI97D028

Figure 35

BP97D060

BI97D027

FIGURE 37

LOWER LOAD OR TOOL

CHAPTER 2 - SAFETY AND DECALS

Figure 38

BI97D020

RAISE LOAD OR TOOL SLOWLY

LOWER LOAD OR TOOL SLOWLY

Figure 39

BI97D034

Figure 41

BI97D026

BI97D033

FIGURE 42

TURN MACHINE LEFT SWING LOAD LEFT

TURN MACHINE RIGHT SWING LOAD RIGHT

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

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

BP97D057

BI97D055

FIGURE 40

RAISE BOOM

FIGURE 43

LOWER BOOM

2-23

CHAPTER 2 - SAFETY AND DECALS

BI97D041

FIGURE 44

BI97D032

RETRACT ARM

BI97D054

2-24

EXTEND ARM

FIGURE 45

FILL TOOL

FIGURE 46

BI97D031

FIGURE 47

EMPTY TOOL

CHAPTER 3 - INSTRUMENTS AND CONTROLS

Chapter 3 INSTRUMENTS AND CONTROLS TABLE OF CONTENTS CAB DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 STEPS AND ACCESS HANDLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 OPERATOR’S COMPARTMENT CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 OPERATOR’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Seat and Control Arm Assembly Forward and Backward Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Armrest Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Headrest Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 FUNCTION CANCELLATION LEVER AND SAFETY BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 RIGHT HAND CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Right Hand Control Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Right Front Console Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Left Hand Control Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Function And Message Display Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Message Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-12 3-11 3-12 3-15 3-16 3-17

CONTROL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 ANTI-THEFT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 AUTOMATIC TEMPERATURE CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

3-20 3-22 3-22 3-22 3-22 3-24 3-24 3-25

TRAVEL CONTROL LEVERS AND PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 FOOT RESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 CAB FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 MACHINE FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

ROPS/FOPS Protective Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

3-36 3-36 3-36 3-39 3-41 3-41 3-42 3-43 3-44

3-1

CHAPTER 3 - INSTRUMENTS AND CONTROLS

NOTES

3-2

CHAPTER 3 - INSTRUMENTS AND CONTROLS

CAB DOORS

3

1 Figure 1

CT06K017

Figure 3

CT06K019

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

WARNING WARNING: Always lock the cab doors in the full open or full closed position before using the handrails on the doors. Failure to comply could result in death or serious injury.

2

WO133A CT06K017

Figure 2

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

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

WARNING WARNING: Clean the steps and access handles to remove all traces of grease, oil, mud, and ice (in winter). Failure to comply could result in death or serious injury.

WO139A

3-3

CHAPTER 3 - INSTRUMENTS AND CONTROLS

STEPS AND ACCESS HANDLES 2 2

2

1 1 CD01K022

1 Figure 4

CD01K022

Figure 5

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

• Always maintain three point support while getting on and off the machine and entering or exiting the operator’s cab. A three point support system has been provided that enables a person to use simultaneously two hands and one foot or two feet and one hand while ascending, descending, or moving about the machine.

• To get in or out of the cab or on to the upper structure, it is imperative that the upper structure frame is in line with the under carriage.

• Never jump down from the machine. When leaving the machine or upper structure, always face the machine and use the steps and access handles.

3-4

CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATOR’S COMPARTMENT CONTROLS WARNING IMPROPER OPERATION OF THIS MACHINE CAN CAUSE DEATH OR SERIOUS INJURY. MAKE SURE THAT EVERY OPERATOR: Learns and practices the safe use of machine controls in a safe, clear area before operating the machine on a job site. Cears the work area of all bystanders. Observes pertinent laws and regulations. Failure to comply could result in deathor serious injury.

WO233A

Figure 6

BS07A127

1. Armrest 2. Seat belt 3. Seat recline lever 4. Operator’s seat 5. Headrest 6. Seat pocket 7. Air conditioner control panel 8. Emergency stop switch 9. Rocker switch (optional)

10. Ashtray 11. Cancellation lever 12. Left tilt lever 13. Left hand control lever 14. Safety bar 15. Seat height knob 16. Slide lever 17. Cup holder 18. Right tilt lever

19. Throttle control 20. Right hand control lever 21. Starter switch 22. Radio 23. Literature holder 24. Storage compartment 25. Storage compartment 26. Travel alarm switch

3-5

CHAPTER 3 - INSTRUMENTS AND CONTROLS

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

8

7 9 4 3 5 1 6

2 Figure 7

BD00J066

SUSPENSION ADJUSTMENT

FORWARD AND BACKWARD ADJUSTMENTS

2 1

CD00F010

Figure 8

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

3-6

CD00F010

Figure 9

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

CHAPTER 3 - INSTRUMENTS AND CONTROLS SEAT POSITION ADJUSTMENT

LUMBAR SUPPORT ADJUSTMENT

3

5 CD00F010

Figure 10

Figure 12

CD00E030

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

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

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

SEAT AND CONTROL ARM ASSEMBLY FORE AND AFT ADJUSTMENT

SEAT BACK ANGLE ADJUSTMENT

6

4

CD00F010

CD00F010

Figure 11

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

Figure 13

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

NOTE: Before tilting the seat back forward, raise the armrests to keep them from contacting the control levers.

3-7

CHAPTER 3 - INSTRUMENTS AND CONTROLS

8

9

7

5

3

4

1

2

6 Figure 14

CT06M007

OPTIONAL AIR RIDE SEAT

1. Combination height and weight adjustment 2. Weight adjustment indicator 3. Forward backward adjustment 4. Seat back angle adjustment 5. Lumbar support adjustment

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

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

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

3-8

CHAPTER 3 - INSTRUMENTS AND CONTROLS

1 2

CT06K046

4

Figure 15

Figure 17

CT06M008

COMBINED HEIGHT AND WEIGHT ADJUSTMENT

SEAT BACK ANGLE ADJUSTMENT

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

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

IMPORTANT: Before tilting the seat back, the armrests must be in the raised position to prevent the armrests from interfering with or bumping the control levers.

3

5 CT06K046

Figure 16

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

CT06K046

Figure 18

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

3-9

CHAPTER 3 - INSTRUMENTS AND CONTROLS HEADREST ADJUSTMENT

8

6

Figure 19

CT06M008

Figure 21

CD00E031

SEAT AND CONTROL ARM ASSEMBLY FORWARD AND BACKWARD ADJUSTMENT

The headrest (8) can be adjusted upward and downward and backward and forward.

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

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

SEAT BELT

ARMREST ANGLE ADJUSTMENT

1 2 3

7 Figure 22

CT06K048 CD00E031

Figure 20

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

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

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

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

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

4. The seat belt will automatically retract.

WARNING Do not make adjustments while the machine is in motion. All seat adjustment should be made with the machine stationary and the parking brake applied.

Failure to comply could result in death or serious injury.

WO133A

3-10

CHAPTER 3 - INSTRUMENTS AND CONTROLS

FUNCTION CANCELLATION LEVER AND SAFETY BAR

2 2 1

1 CT06K029

Figure 23

CD00E006

Figure 24

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

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

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

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

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

WARNING Unexpected machine movement! Before leaving the operator's compartment, the function cancellation lever must be in the central position and the safety bar must be in the inward position. Failure to comply could result in death or serious injury.

WO233A

3-11

CHAPTER 3 - INSTRUMENTS AND CONTROLS RIGHT HAND CONSOLE

5

3 1

2

4 6

7

6

Figure 25

CT06K22

1. MONITOR PANEL The monito r panel displays machine system conditions and will check each monitored system when the engine is turned on.

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

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

8

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

5. HOUR METER/TRIP The machine hour meter registers engine operation hours and tenths of an hour (6 minutes) and allows m ainte nan ce inte r vals to b e calcu la ted . The hourmeter can be read even when the engine is off.

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

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

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

3-12

CHAPTER 3 - INSTRUMENTS AND CONTROLS RIGHT HAND CONTROL ARM

12 9

10

14

13 15 11

9 Figure 26

CT06K22

9. OPTION CONTROL (IF EQUIPPED) 10. ENGINE IDLE SPEED SELECTOR This control enables automatic engine idle without operating the throttle button. To select idle speed, press and release the control, and the engine will automatically go into idle speed. The message “Eng. Idling” will appear on the monitor display panel (1).

When the control is pressed and released once more the engine will revert to its original speed, and the message on the monitor display panel will disappear.

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

NOTE: Always stop the engine when making adjustment to the control arm.

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

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

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

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

12. STARTER SWITCH The starter switch has four positions:

Start: Engine starting position.

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

Acce sso r y: Engine in stop ped p ositio n with accessory power on.

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

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

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

3-13

CHAPTER 3 - INSTRUMENTS AND CONTROLS RIGHT FRONT CONSOLE CONTROLS

1 2

3

3 4

5

CT06K023

Figure 27

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

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

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

4. Storage Compartment 5. Cigarette Lighter Press the lighter in and release to activate. Do not hold the lighter in. If the lighter does not come out after 30 seconds, pull it out manually, as it may damage the electrical circuit. When the lighter has been removed the socket can be used as a 24 volt electrical socket.

3-14

CHAPTER 3 - INSTRUMENTS AND CONTROLS LEFT HAND CONTROL ARM

1

2 3

4

4 8

6

7

5 Figure 28

CT06024

1. Emergency Stop Switch

5. Radio Mute

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

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

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.

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

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

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

IMPORTANT: Always operating the machine.

4. Option Control

sound

the

horn

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

6. Arm Angle Adjustment Lever

WARNING Equipment failure could cause accident or injury!

Before operating the machine, check for correct operation of steering, brakes, hydraulic controls, instruments, and safety equipment. Make sure the transmission control lever is in the neutral position.

Make all adjustments before operating the machine.

Failure to comply could result in death or serious injury.

before

WO204A

7. Ashtray Pull ashtray upward to empty.

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

3-15

CHAPTER 3 - INSTRUMENTS AND CONTROLS FUNCTION AND MESSAGE DISPLAY SCREEN

Figure 29

CT06K027

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

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

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

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 13 under “Right-hand control arm”.

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

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

7. OPERATING ICONS

Engine idling

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

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

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

Pressure increase

Automatic heating

Fan ON

Engine preheat 8. ACCESSORY ICON Displays the type of accessory in use by the machine (i.e. hydraulic hammer, etc.).

3-16

CHAPTER 3 - INSTRUMENTS AND CONTROLS MESSAGE DISPLAY

BS07B380

Figure 30

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

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

AUTO WARM UP - This message shows that engine temperature is automatically rising to operating temperature. It disappears once the engine has reached operating temperature or when the engine idle speed selector, the throttle control button, or a control lever is operated.

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

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

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

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

3-17

CHAPTER 3 - INSTRUMENTS AND CONTROLS MESSAGE DISPLAY

BS07B380

Figure 31

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

LOW OIL PRESS - This message shows that the engine oil level is low. The audible alarm device also sounds.

Shut the engine off, remove the starter switch key and check the oil level. See “Engine” in the “Lubrication/Filters/Fluids” Section.

OVER HEAT - This message shows that the temperature of the engine coolant or the hydraulic fluid is too high.

The audible alarm device also sounds. Reduce engine speed. If the temperature does not drop, shut the engine off, remove the starter switch key and find the cause of the problem.

ALTERNATOR - This message shows that the alternator is defective. The audible alarm device also sounds.

Shut the engine off, remove the starter switch key and check the alternator. See your Case Dealer.

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

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

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

See the “Lubrication and Maintenance” Section.

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

Check engine electric circuit related items.

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

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

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

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

3-18

CHAPTER 3 - INSTRUMENTS AND CONTROLS

1

TRIP

ODO

12345.6

1/10H

AUTO

n n/min

Figure 32

BS07B381

TRAVEL SPEED SELECTOR - This is a push button for changing from high speed to low speed and low to high. High or low speed will be indicated on the working mode selector of the display monitor. When high speed is chosen the indicator light (1) to the upper left of the switch will illuminate. In low speed the indicator light is off.

CT06K0026

TRIP

Figure 33

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

TRIP SWITCH

WARNING Travel speed should be such that complete control and machine stability is maintained at all times.

Changes in speed while the machine is motion can cause unexpected movement. Where possible, avoid operating near ditches, embankments and holes. Reduce speed when turning, crossing slopes, and on rough, slick, or muddy surfaces. Failure to comply could result in death or serious injury.

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

WO233A

Low speed (I), 0 to 2.8 km/hr (0 to 1.7 mph) Select this speed to travel on slopes, rough ground or soft terrain.

High speed (II), 0 to 5.4 km/hr (0 to 3.4 mph) 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 drops down to 1st speed. The system automatically returns to 2nd speed as soon as the hydraulic system is no longer overloaded.

3-19

CHAPTER 3 - INSTRUMENTS AND CONTROLS

CONTROL SWITCH

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

2

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

1

3

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

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

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

4 BS07B382

Figure 34

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

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

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

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

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

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

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

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

3-20

CHAPTER 3 - INSTRUMENTS AND CONTROLS

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

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

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

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

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

BS07B385

Figure 37

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

BS07B383

Figure 35

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

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

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

(3) Wiper switch increases the code number.

(4) Auto idling switch decreases the code number.

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

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

BS07B384

Figure 36

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

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

3-21

CHAPTER 3 - INSTRUMENTS AND CONTROLS

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

6

3

9

7

2 4

1

8 5

Figure 38

CD00E033

1. On/Off

6. Air recycling

2. Automatic

7. Air flow direction control

3. Air conditioning

8. Windshield defroster

4. Fan speed

9. Display screen

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

ON/OFF

FAN SPEED

9

4 1 CD00E048

Figure 39

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 selected for previous use.

3-22

CD00E048

Figure 40

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

CHAPTER 3 - INSTRUMENTS AND CONTROLS TEMPERATURE

AIR FLOW DIRECTION

9 9

7 5 Figure 41

CD00E049

Figure 43

CD00E050

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

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

- Via the top front air vent.

- Via the top front and rear air vents.

- Via the top and lower rear air vents.

- Via the lower rear and windshield air vents.

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

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

AIR RECYCLING

6

WINDSHIELD DEFROSTER

99

9

CD00E050

Figure 42

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

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

8 CD00E050

Figure 44

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

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

To turn the defroster off, press the button once more and the indication on the display screen will disappear.

3-23

CHAPTER 3 - INSTRUMENTS AND CONTROLS 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. If the cab door or front window is opened, the AC system will select the face vent as the flow direction and reduce the fan speed automatically.

MANUAL

6

3

9

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

AUTOMATIC

7 9

5 2

CD00E49

4 Figure 46

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), and (7).

CLIMATE CONTROL SENSOR

5 CD00E049

1 Figure 45

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

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

CD00E051

Figure 47

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

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.

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

3-24

CHAPTER 3 - INSTRUMENTS AND CONTROLS RADIO

Figure 48

GRAPHIC_1D

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

2. Tone Control Adjustments can be made to tone by tuning to decrease high sound interference.

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

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

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

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

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

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

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

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

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

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

3-25

CHAPTER 3 - INSTRUMENTS AND CONTROLS Presetting Radio Stations

Setting the Radio Clock

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

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

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

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

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

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

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

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

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

Radio Mute Switch

CT06K031

Figure 49

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

3-26

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

1 9

4

3

2 SWING LEFT

ARM OUT

3

1 SWING RIGHT

ARM IN

2

4

Figure 50

BC00J123

1.Arm out

3.Swing left

2.Arm in

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

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

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

3-27

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

5 9

7

8

6 BUCKET RETRACT

BOOM DOWN

7

5 BOOM UP

BUCKET EXTEND

6

8

Figure 51

BC00J122

5.Boom down

7.Bucket close (retracts)

6.Boom up

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

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

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

3-28

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

1 9

4

3

2 BOOM DOWN

SWING LEFT

3

1 BOOM UP

SWING RIGHT

4

2

Figure 52

BC00J125

1.Boom down

3.Swing left

2.Boom up

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

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

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

3-29

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

5 9

7

8

6 ARM OUT

BUCKET RETRACT

7

5 ARM IN

BUCKET EXTEND

6

8 Figure 53

BC00J124

5.Arm out

7.Bucket close (retracts)

6.Arm in

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

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

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

3-30

CHAPTER 3 - INSTRUMENTS AND CONTROLS

TRAVEL CONTROL LEVERS AND PEDALS

Figure 54

CD00E012B

Figure 55

CD00E012B

TRAVEL CONTROL LEVERS

TRAVEL CONTROL PEDALS

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

IMPORTANT: Travel speed either forwards or in reverse depends on the position of the travel speed selector. See “Systems display panel”.

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

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

FOOT RESTS

Figure 56

CD00E012B

FOOTREST

3-31

CHAPTER 3 - INSTRUMENTS AND CONTROLS FUSE BOX

1

CT06M006

Figure 57

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

CT06K036

Figure 58

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

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

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

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

CT06K037

Figure 59

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

3-32

CHAPTER 3 - INSTRUMENTS AND CONTROLS

CAB FEATURES CAB LIGHT CAB DOOR SLIDING WINDOWS

CT06K34

Figure 60

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

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

CT06K044

Figure 63

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

CUP HOLDER

COAT HANGER

CT06K043

CT06K035

Figure 61

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

STORAGE COMPARTMENTS

LITERATURE RACK

CT06K040 CT06K042

Figure 62

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

Figure 64

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

Figure 65

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

3-33

CHAPTER 3 - INSTRUMENTS AND CONTROLS STORAGE COMPARTMENT

ROOF CURTAIN (Optional Skylight)

CT06K038

Figure 66

Figure 68

CT06K040

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

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

ROOF HATCH (Optional)

EMERGENCY EXIT (Rear Window)

2 1

CD00E015

Figure 67

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

IMPORTANT: The roof hatch closing is assisted by two gas struts, Follow through the closing movement only without “forcing”.

Figure 69

CT06K054

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

WARNING Do not obstruct the rear window emergency exit should it be necessary to evacuate the machine.

Failure to comply could result in injury or death

3-34

CHAPTER 3 - INSTRUMENTS AND CONTROLS WINDSHIELD SUN SCREEN

CLOSING

Figure 70

CT06K051

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

TO OPEN THE WINDSHIELD

CD00E052

Figure 73

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

LOWER FRONT WINDOW

2

1

CT06K051

Figure 71

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

CT06K052

CT06K053

Figure 74

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

Figure 72

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

CD0E022

Figure 75

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

3-35

CHAPTER 3 - INSTRUMENTS AND CONTROLS

MACHINE FEATURES ENGINE DOORS

WARNING Moving parts! Make sure all entry and mechanical access doors are properly closed before operating the machine. Failure to comply could result in death or serious injury.

W0238A

WARNING

Figure 76

CT07A063

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

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

Figure 77

CT07A064

The left hand door gives access to the batteries, windshield washer reservoir, air filter, radiator, overflow reservoir, oil cooler, etc.

WARNING Moving parts! Make sure all entry and mechanical access doors are properly closed before operating the machine. Failure to comply could result in death or serious injury.

W0238A

3-36

A v o i d i n j u r y a n d /o r m a c h i n e d a m a g e ! A f t e r installation or service, make sure you remove all tools from the machine. Failure to comply could result in death or serious injury.

W0902A

CHAPTER 3 - INSTRUMENTS AND CONTROLS ENGINE HOOD OPENING

WARNING Make sure all doors and hood are properly closed before driving the machine. Failure to comply could result in deathor serious injury.

W0280A

CT07A065

Figure 78

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

CLOSING

CT07S066

Figure 79

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

CT06K063

Figure 80

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

3-37

CHAPTER 3 - INSTRUMENTS AND CONTROLS REAR VIEW MIRRORS

CD00E036

Figure 81

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

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

FRONT STORAGE BOX

CT07062

Figure 82

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

NOTE: Use the starter switch key to lock and unlock the storage box cover. Make sure the storage box cover is properly closed before moving the machined.

3-38

CHAPTER 3 - INSTRUMENTS AND CONTROLS FUEL TANK

CT070A061

Figure 83

CT07A071

Use the correct fuel grade for the operating season.

The starter switch key to lock and unlock the cap.

Figure 84

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

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

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

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

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

WARNING Fuel vapors are explosive and flammable. Do not smoke while handling fuel. Keep fuel away from flames or sparks. Shut off engine and remove key before servicing. Always work in a well-ventilated area. Clean up spilled fuel immediately. Failure to comply could result in death or serious injury.

W0940A

3-39

CHAPTER 3 - INSTRUMENTS AND CONTROLS WINDSHIELD WASHER RESERVOIR

LOWER PANELS

CT070A67

Figure 85

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

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

CT07A068

Figure 86

This reser voir is located in the left hand rear compartment. It is equipped with an electric pump which is operated from the control panel. See Systems Display and Control Panel section IMPORTANT: Never operate the windshield washer control when the reservoir is empty. This could cause damage to the electric pump.

Remove the cap to fill the reservoir.

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

3-40

CHAPTER 3 - INSTRUMENTS AND CONTROLS TOWING HOLES

LOAD LIFTING EYE

Figure 87

CD00E069

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

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

Figure 88

BD00J053

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

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

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

Failure to comply could result in death or serious injury.

W0286A

WARNING DO NOT exceed 32 km/h (20 mph) when towing the machine. Failure to comply could result in death or serious injury.

WARNING Never weld hooks or lugs on the bucket for handling operations. The only attachment point which may be used is the bucket lifting eye. Failure to comply could result in injury or death.

D0049A

D0017A

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

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

3-41

CHAPTER 3 - INSTRUMENTS AND CONTROLS

WARNING After an accident, fire, tip over, or roll over, a qualified technician MUST replace the Roll Over Protect Structure (ROPS) before returning the machine to the field or job site. Failure to comply could result in injury or death.

W0134A

Figure 89

CD04D008A

FALLING OBJECTS PROTECTIVE STRUCTURE R O L L OV E R P R OT E C T I V E S T R U C T U R E (OPTIONAL) A FOPS (Falling Objects Protective Structure) ROPS (Roll Over Protection Str ucture) is an important protective element when work takes place in areas where stones or debris may fall. See your CASE dealer for this protective piece of optional equipment and its proper installation.

WARNING WARNING: The Protective Structure and interconnecting components are a certified system.

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

DO NOT WELD, DRILL HOLES, ATTEMPT TO STRAIGHTEN OR REPAIR THE PROTECTIVE STRUCTURE. MODIFICATION IN ANY WAY CAN REDUCE THE STRUCTURAL INTEGRITY OF THE STRUCTURE WHICH COULD CAUSE DEATH OR SERIOUS INJURY IN THE EVENT OF FIRE, TIP, ROLLOVER, COLLISION OR ACCIDENT. Failure to comply could result in injury or death.

D0049A

3-42

CHAPTER 3 - INSTRUMENTS AND CONTROLS HOSE BURST CHECK VALVE (OPTIONAL) SERVICE SPECIFICATIONS Check by your CASE Dealer . . . . . . .Every 6 months

CT07A069

Figure 90

The role of the load holding valve is to stop the attachment from dropping due to valve spool leakage in neutral position or in the event of a line or hose accidentally breaking.

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

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

3-43

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

WARNING Fuel vapors are explosive and flammable. Do not smoke while handling fuel. Keep fuel away from flames or sparks. Shut off engine and remove key before servicing. Always work in a well-ventilated area. Clean up spilled fuel immediately. Failure to comply could result in death or serious injury.

W0940A

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

CT07A071

5. Remove the fuel tank filler cap.

CT06K069

CT06K068

Figure 91

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

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

Figure 93

Figure 94

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

1

CT06K068 PDF0361

Figure 92

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

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

3-44

Figure 95

7. Turn the switch located to the “On” position.

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

CHAPTER 4 - OPERATING INSTRUCTIONS

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

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

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

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

4-5 4-5 4-5 4-5

BASIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking the Machine and Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Bringing the Machine Up To Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6 4-6 4-7 4-8

CHECKING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Operating the Machine In Cold Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Operating the Machine in Hot Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 MACHINE TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting Loads With the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Operating the Machine in Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating the Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Towing the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-11 4-13 4-14 4-17 4-18 4-19 4-20

TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

By Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 On a Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

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CHAPTER 4 - OPERATING INSTRUCTIONS

NOTES

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CHAPTER 4 - OPERATING INSTRUCTIONS

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

2. Keep the engine at normal operating temperature.

3. Do not run the engine at idle speeds for long periods of time 4. Adhere to scheduled maintenance intervals - See Chapter 5.

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

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

SB055

BEFORE OPERATING THE MACHINE Before operating this machine, be sure to do the following:

• Check the level of all fluids (engine oil, hydraulic fluid and coolant) and make sure that the fluids and lubricants are suitable for prevailing conditions. See “Fluids and Lubricants” in the “Lubrication/Filters/Fluids” Section and “Operating the Machine in Cold Weather”.

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

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

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

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

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

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

• Remove any obstructions which hinder visibility.

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

• Check that no tools or other items have been left on the machine. Check on the undercarriage and the upper structure and in the operator’s compartment.

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

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

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

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

• Clean or replace any decals which are illegible.

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

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

4-3

CHAPTER 4 - OPERATING INSTRUCTIONS

• See “Handling the Machine” when it is necessary

MACHINE OPERATION

to lift the machine.

• See “Towing the Machine” when it is necessary to WARNING

tow the machine.

MAKE SURE THAT EVERY OPERATOR: -learns and practices the safe use of machine controls in a safe, clear area before operating the machine on a job site. -clears the work area of all bystanders.

-observes pertinent laws and regulations. Failure to comply could result in death or serious injury.

WO198A

• When operating the machine, be sure to do the following:

• When starting the engine, be sure to use the correct procedure for the prevailing weather conditions. See “Starting the Engine”.

• Regularly consult the hourmeter to ensure that all servicing operations are carried out punctually.

See “Service Intervals”.

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

• See “Break In Period” if the machine is new or if the engine has been reconditioned.

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

• Do not work near overhead high-voltage electric lines without checking beforehand that all necessary measures have been taken to respect the minimum distances:

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

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

• Never operate the working or travel controls

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

• Never use the attachment or bucket for sweeping the ground to level out rubble or push objects creating transversal stress on the attachment.

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

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

• In the event of an operating problem or failure, move the machine to a safe place, lower the attachment to the ground, stop the engine and remove the starter switch key. Place a Do Not Operate tag on the machine. Locate the problem, report it, if necessary, and take the necessary steps to warn others not to attempt to operate the machine.

• Do not stop the engine without taking prevailing weather conditions into “Stopping the Engine”.

consideration.

See

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

OPERATING INSTRUCTIONS

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

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

unless you are properly seated in the operator’s seat with the seat belt correctly fastened.

• Modify your driving to suit working conditions

• Modify your driving to suit the type of work and

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

working conditions. See “Operating Instructions”.

• Do not allow anyone to stand in the machine

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

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

• When traveling at right angles to the slope, move

• Operate all controls gradually to ensure smooth

on to the slope at low speed. Never reduce engine speed when traveling down slopes.

machine operation.

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

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

4-4

• 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.

CHAPTER 4 - OPERATING INSTRUCTIONS

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

• The following operations are likely to damage the machine. Do not perform: 1. Excavation using the weight of the machine as a force of impact.

2. Excavation using the machine’s travel force.

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

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

• When climbing up a slope, place the attachment about 250 mm (10 inches) above the ground.

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

• Avoid turning the machine on steep slopes.

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

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

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

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

1. Check for leaks under the machine.

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

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

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

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

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

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

STARTING THE ENGINE 1. Adjust the seat and fasten your seat belt. Make sure you can operate the pedals correctly with your back against the seat cushion.

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

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

NOTE: The Direction Control Lever must be in Neutral or the engine will not crank.

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

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

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

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

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

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

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

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

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

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

4-5

CHAPTER 4 - OPERATING INSTRUCTIONS

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

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

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

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

5. Check all instruments are operating correctly.

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

7. Unlock the upper structure swing function.

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

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

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

2. Lower the attachment to the ground.

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

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

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

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

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

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

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

WO269A

4-6

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

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

WARNING WARNING: Explosion Hazard. DO NOT use ether starting fluid. Serious engine damage, explosion, death, or serious personal injury could occur. Failure to comply could result in death or serious injury

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

WO148A

IMPORTANT: This engine is equipped with a glow plug heater; DO NOT USE ANY TYPE OF STARTING FLUID. 1. Sit correctly in the operator’s seat with the seat belt properly fastened. See “Operator’s Seat” in the “Controls/Instruments/Accessories” Section.

Figure 3

CT06K078

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

7. When the message disappears, turn the key to the “START” position. Release the key as soon as the engine starts to turn. If the engine stops, wait about a minute before trying to start the engine again.

CT06K029

Figure 1

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

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

1 2

CD00E060

CD00E060

Figure 2

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

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

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

Figure 4

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

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

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

4-7

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

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

Engine Automatic Warm-up

Hydraulic Oil Warm-up

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

Turn the engine throttle button to half-open position.

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

Engine Manual Warm-up

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

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

Continue the extending and retracting procedure until the temperature rises. See “Systems Display and Co ntr ol Pa ne l” in the “Co ntr ols/I nstr u me nt s/ Accessories” Section.

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

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

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

• Let the engine run at idle speed until the engine

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

and hydraulic oil reaches normal operating temperature.

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

• Once normal operating temperature has been reached, check the following : 1. The exhaust smoke is normal.

2. There is no abnormal noise or vibration.

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

4-8

Check the systems display and control panel regularly.

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

• • • •

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.

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

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

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

Fuel a) To prevent condensation forming and water getting into the fuel system, fill the fuel tank after each day’s work and drain off any water before starting the next day’s work. b) To prevent crystals forming at -2° C (29° F), use fuel which is rated for the ambient temperature.

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

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 when operating in extremely dusty conditions.

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

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

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

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

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

Engine Preheat Check the message display screen. The engine preheat indicator will show that the engine needs preheating and that glow plugs are functioning. The length of time this message remains is dependent on the coolant temperature. As soon as the engine reaches starting temperature, the audible alarm will sound.

4-9

CHAPTER 4 - OPERATING INSTRUCTIONS STOPPING THE ENGINE

CT06M012

Figure 5

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

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

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

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

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

4-10

CT06K024

Figure 6

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

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

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

CHAPTER 4 - OPERATING INSTRUCTIONS

MACHINE TRAVEL WARNING Controls can be reversed! In the normal travel position, the operator's compartment is above the idler wheels and the travel reduction gears are to the rear of the upper structure. If the upper structure is turned 180 degrees in relation to the undercarriage, the controls are reversed. Failure to comply could result in death or serious injury.

WO289A

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

Traveling In A Straight Line (Forward)

GCS98M546

Turning To The Left (Forward)

Figure 7

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

CS98M548

Figure 9

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

Turning To The Right (Forward)

Traveling In A Straight Line (In Reverse)

CS98M551 CS98M547

Figure 8

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

Figure 10

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

4-11

CHAPTER 4 - OPERATING INSTRUCTIONS Turning To The Left (In Reverse)

CS98M549

Turning On The Spot, To The Left

Figure 11

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

Turning To The Right (In Reverse)

CS98M550

CS98M553

Figure 14

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

Gradual Turn On The Move

Figure 12

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

Turning On The Spot, To The Right

CS98M545

Figure 15

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

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

CS98M552

Figure 13

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

4-12

CHAPTER 4 - OPERATING INSTRUCTIONS LIFTING LOADS WITH THE MACHINE

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

SB055

This machine is not a crane. Be very careful when you lift a load. Do not exceed lifting capacities.

IMPORTANT: See the lifting chart in the cab of your machine.

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

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

• Be careful to balance the load correctly.

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

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

• When the load is raised, keep all persons away until the load is placed on blocks or on the ground.

• With the tracks and side frame in the transport Figure 16

BD02D152

position no working functions may be performed.

LOAD LIFTING CHART IN CAB

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

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

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

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

BD00J053

Figure 17

LOAD LIFT POINT ON BUCKET - ATTACH RIGGING HERE

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

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

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

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

4-13

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

A H SP

1

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

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

CT06K086

Figure 20

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

Figure 18

CT06K067

Using a hexagonal wrench, open the supply valves.

1

CT06K083

2

Figure 19

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

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

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

4-14

CHAPTER 4 - OPERATING INSTRUCTIONS CHANGING THE FLOW PATTERN

2 1 4567

2

AUTO

n n/min

H

E

F

4 3 Figure 24

CT06K026

Figure 21

CT06K083

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

A H SP

1

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

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

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

Figure 22

CT06K086

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

Pattern

Flow rate per minute 1 Pump Flow

2 Pump Flow

1

37.5 gal. (142 L)

75 gal. (284 L)

2

34.9 gal. (132 L)

72.4 gal. (274 L)

3

32.2 gal. (122 L)

69.7 gal (264 L)

4

29 gal. (110 L)

66.6 gal. (252 L)

5

25.1 gal. (95 L)

62.6 gal. (237 L)

Figure 23

6

21.9 gal. (83 L)

59.4 gal. (225 L)

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

7

18.5 gal. (70 L)

56 gal. (212 L)

8

15.1 gal. (57 L)

52.6 gal. (199 L)

9

11.4 gal. (43 L)

48.9 gal. (185 L)

10

19.2 gal. (35 L)

46.8 gal. (177 L)

A H SP

3

386

BS07B127

4-15

CHAPTER 4 - OPERATING INSTRUCTIONS OPTIONAL JOYSTICK CONFIGURATION

1 2 5

3

4 6

Figure 25

CT06K024B

Figure 26

CT06K022B

LEFT HAND JOYSTICK

RIGHT HAND JOYSTICK

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

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

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

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

4-16

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

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

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

CHAPTER 4 - OPERATING INSTRUCTIONS OPERATING THE MACHINE IN WATER

Figure 27

CS99A825

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

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

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

IMPORTANT: Do not operate in a fast flowing stream.

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

OPERATING THE MACHINE ON SLOPING GROUND

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

W0144A

• Use extreme caution on hillside operations.

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

• When digging on a slope, avoid swinging the upper structure towards the bottom of the slope with the bucket full. Always keep the travel reduction gears pointing down towards the bottom of the slope.

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

4-17

CHAPTER 4 - OPERATING INSTRUCTIONS OPERATING THE BUCKET Filling Maneuver the arm to fill the bucket. Keep the bottom of the bucket parallel to the cut. The bucket teeth and blade must cut the ground like the blade of a knife. The depth of dig varies depending on the type of material.

EXCAVATING METHOD

PDH0493M

Figure 28

PDH0494M

Figure 29

CORRECT

4-18

WRONG

WRONG

The bucket will dig in and cause a stall.

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

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

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

CT06M029

Figure 32

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

CD00E010

Figure 30

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

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

CT06K017

Figure 33

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

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

CT06M022

Figure 31

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

4-19

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

Wherever possible, carry out any repairs at the site. Towing should be done only a short distance and at slow speeds. Tow only if it is unavoidable.

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

Failure to comply could result in death or serious injury.

WO296A

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

WO259A

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

CT06K082

CT06M021

Figure 34

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

CT06K030

Figure 35

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

4-20

Figure 36

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

CHAPTER 4 - OPERATING INSTRUCTIONS

TRANSPORTING THE MACHINE

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

ON A TRAILER

WARNING The machine can slip or fall from a ramp or trailer. Make sure the ramp and trailer are not slippery. Remove all oil, grease, ice, etc. Move the machine on or off the trailer with machine centered on the trailer or ramp.Failure to comply could result in death or serious injury WO1452A

WARNING Clear the area around and under the counterweight removal and installation system before installing or removing counterweights. Keep all unauthorized personnel clear of the area. Make sure all lifting devices are in good condition and capable of handling the counterweight mass. Failure to comply could result in death or serious injury.

WO037A

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. It may be necessary to remove the counterweight.

Loading

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

Select low travel speed, the indicator lamp to the l e f t o f t r a ve l s p e e d s e l e c t o r w i l l n o t b e illuminated.

Machine with Attachment

Figure 37

CD95M248

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

Install the trailer side extensions (if fitted).

PDH0248

Figure 39

v

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

Raise the attachment and bring it about 7-8 inches (20 cm) above the bed of the trailer. !4567

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

2

AUTO

n n/min

H

E

F

2 1 CD00E010

Figure 38

4-21

CHAPTER 4 - OPERATING INSTRUCTIONS Stop the engine, remove the starter switch key, raise the function cancellation lever (with the safety bar inward).

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

Fold the rear view mirrors inwards. Retract the radio aerial, if equipped.

PDH0250

Figure 40

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

Machine without Attachment CS99B518

Figure 43

3. Use blocks and chains to fasten the machine to the trailer.

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

Unloading CD00E150

Figure 41

Move 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.

1. Keep all unauthorized personnel clear of the area.

Remove the blocks and fastening chains.

2. Start the engine.

3. Unlock the upper structure swing function.

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

5. Select low travel speed and slowly move off the trailer.

6. Turn the rear view mirrors back to their correct position.

7. For machines without attachments, reinstall the arm, counterweight, and attachment.

8. When the attachment has been installed, all air must be removed from the hydraulic circuit and the machin e should b e tested for correct operation. Check the hydraulic fluid level.

CD00E150

Figure 42

Place the machine at the front of the trailer and swing the upper structure 180 degrees.

4-22

CHAPTER 4 - OPERATING INSTRUCTIONS

MACHINE STORAGE Preparation For Storage

Periodical Checks

The following procedure applies when the machine is to be stored for a month or more. Store the machine on flat, level ground, inside a building. If a building is not available, park the machine in a dry area on planks and use wheel chocks, front and rear. Cover the machine with a waterproof covering. Before stor ing the m a ch ine, carr y out the fo llowing operations:

Every month, check: A. The electrolyte level in the batteries and the battery charge. Recharge the batteries if necessary.

B. The grease on the cylinder rods.

C. The fuel level in the fuel tank and the oil level in the engine. Add more fluids, if necessary.

1. Clean the machine completely and lubricate all components equipped with grease fittings.

D. The condition of all lines, connectors, and clamps (rust). Lubricate, if necessary.

2. Drain the water from the cooling system. If the system is filled with an antifreeze mixture, this operation is not necessary.

E. The condition of the paint. Apply a coat of anti-rust treatment where necessary.

3. To avoid rust, it is necessary to refill the fuel tank completely.

4. Crank the engine a few turns to spread a protective film on the cylinder walls.

5. If possible, store the batteries in a place where there is no danger of freezing. Recharge them monthly.

6. To ensure adequate protection of the transmission components, at least once a month, t h e m a c h i n e s h o u l d b e m o ve d fo r s h o r t distances, so that a film of oil is renewed on the parts.

7. Place a Do Not Operate tag on the key switch in a visible position.

Starting Up After Storage 1. Close the drain valves and fill cooling system.

2. Drain the fuel tank and fill with clean diesel fuel.

3. Drain the engine sump, fill with clean engine oil and check the oil level.

4. Change the fuel filter.

5. Install the batteries.

6. Lubricate the machine thoroughly.

7. Check the condition of the fan drive belt and replace it if necessary.

8. Check the hydraulic fluid level and add more fluid if necessary.

9. Check the travel gear oil level and add more oil if necessary.

10. Clean the cylinder rods.

11. Remove the Do Not Operate tag and start the engine, following the starting up procedure.

12. Keep a careful watch on all systems display panel lamps and indicators.

4-23

CHAPTER 4 - OPERATING INSTRUCTIONS

NOTES

4-24

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

Chapter 5 LUBRICATION, FILTERS, AND FLUIDS TABLE OF CONTENTS GENERAL SAFETY BEFORE YOU SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Releasing Pressure in the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bleeding Air from the Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Systemgard® Lubrication Analysis Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3 5-4 5-5 5-6 5-6

FLUIDS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Reservoir/Transmission Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Travel Reduction Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing Reduction Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7 5-7 5-7 5-7 5-7 5-7 5-7

LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Oil Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Viscosity/Temperature Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Daily/Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

500 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5000 Hour Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-10 5-10 5-10 5-12 5-13 5-24 5-28 5-38 5-41

5-1

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

NOTES

5-2

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

GENERAL SAFETY BEFORE YOU SERVICE SERVICING INSTRUCTIONS

WARNING Always remove all pressure before working on the hydraulic system. Follow the pressure BLEED program in the Configuration Mode to remove the pressure in the entire hydraulic system. Failure to comply will result in death or serious injury.

D0035A

Comply promptly with maintenance intervals by checking the hourmeter every day. Before starting maintenance, park the machine on firm, level ground, away f r o m a ny o b s t a c l e s w i t h t h e bu cke t o r attachment on the ground. Keep all unauthorized personnel clear of the area. Unless otherwise specified, all maintenance operations should be carried out with:

• • • • • • •

the engine stopped the parking brake engaged

WARNING Pressurized hydraulic fluid can penetrate the skin and cause severe injuries. Hydraulic fluid is under extreme pressure. Rest the bucket or attachment on the ground. Shut the engine off, turn the key on, and move the hydraulic control lever through all movements several times to relieve residual pressure in the system. Failure to comply could result in death or serious injury.

WO161A

the key removed from the starter switch a Do Not Operate tag placed on the key switch all circuits cooled down before starting work all hydraulic pressure released any accumulator pressure released for the appropriate circuit

• all non-authorized personnel clear of the machine operating area Clean the grease fittings before lubrication. Clean around plugs and filler holes before adding fluid. No dust or dirt must enter the components or the circuits.

Wear suitable clothing, and remember to use the necessary safety equipment.

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

CENA000

WARNING Before attempting any service procedure, it is your responsibility to know the number of accumulators on the machine, and the correct procedure for releasing the pressure of each accumulator. Failure to comply could result in death or serious injury.

CENA000

When carrying out service work on the machine, place a Do Not Operate or warning tag on the instrument panel or key switch. Never climb down from the operator's compartment leaving the engine running.

Any modification to this machine without prior authorization could cause serious injury. Do not make any modifications without authorization.

Consult your Case Dealer.

The service intervals in this chapter refer to normal operating conditions. During the first operation period of a new machine or rebuilt component and/or under particularly severe conditions the service intervals should be carried out more frequently.

IMPORTANT: Take particular care to replace all filters regularly. Clean filters mean longer engine running life. Use genuine Case replacement filters and oil for maximum service intervals.

IMPORTANT: Oils and fluids must be disposed of properly. Be aware of environmental issues.

5-3

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS RELEASING PRESSURE IN THE HYDRAULIC SYSTEM IMPORTANT: Before carrying out any work on the hydraulic system, there should be no pressure in any of the circuits.

Allow the hydraulic oil in the system to cool before performing any maintenance on the hydraulic system.

1. Keep all unauthorized personnel clear of the area. Park the machine on firm, level ground.

Lower the attachment to the ground, and stop the engine.

Figure 3

CD00E11

4. Operate the control levers from right to left and front to rear approximately a dozen times. Turn the starter key to the OFF position.

CT06M021

Figure 1

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

Figure 4

CD01N035

5. Unscrew the hydraulic reservoir protective cap and remove it.

breather

6. Press the button on top of the breather to release any residual pressure.

CT06K030

Figure 2

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

WARNING Hydraulic fluid or grease injected into your skin can cause severe injury or death. Keep your hands and body away from any pressurized leak. Use cardboard or paper to check for a leak. If fluid is injected into your skin, see a doctor immediately and have the fluid removed. Failure to comply could result in death or serious injury.

WO198A

WARNING Before carrying out any service work on the hydraulic system, it is necessary to allow it to cool (the temperature should not be more than 40°C (104° F). Failure to comply could result in death or serious injury.

WO198A

5-4

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS BLEEDING AIR FROM THE HYDRAULIC COMPONENTS

WARNING Hydraulic fluid or grease injected into your skin can cause severe injury or death. Keep your hands and body away from any pressurized leak. Use cardboard or paper to check for a leak. If fluid is injected into your skin, see a doctor immediately and have the fluid removed. Failure to comply could result in injury or death.

W098A

WARNING The hydraulic tank is a pressurized system. Vent tank slowly by loosening the breather before performing work on the hydraulic system. Failure to comply could result in injury or death.

W1047A

IMPORTANT: After bleeding air from the components, stop the engine for five minutes and check to make certain there are no bubbles at the surface of the hydraulic fluid in the reservoir.

Hydraulic Pump

CD01N038

Hydraulic Swing Motors

Figure 5

Keep all unauthorized personnel clear of the area.

Clean around the air bleed plug. Loosen the air bleed plug, remove the plug if the fluid does not flow.

Fill the pump with hydraulic fluid through this port until the fluid comes up to the edge of the port. Install and tighten the air bleed plug.

Start the engine and run it at low 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.

Attachment Cylinders Keep all non-authorized personnel clear of the area.

Start and run the engine at low idle speed. Extend and retract the attachment cylinder rods four or five times without bringing the cylinders to the end of the stroke. Then repeat the operation three or four times, this time bringing the cylinder rods to the end of stroke.

CD01N028

Figure 6

Keep all non-authorized personnel clear of the machine. Start and run the engine at low idle speed.

Loosen the unions on the top of the swing motors to release any air.

Retighten the unions as soon as the fluid flows out of the ports.

After the warm up procedure is completed, move each control slowly several times to remove any air in the system.

Swing the upper structure evenly left to right two complete turns or more.

Stop the engine, and wait five minutes.

Check the oil level in the hydraulic reservoir, and add oil as required. Be certain there are no air bubbles in the hydraulic reservoir.

5-5

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS SYSTEMGARD® LUBRICATION ANALYSIS PROGRAM

ENGINE HOURMETER Service your machine at the intervals and locations given in the Quick Reference Lubr ication Maintenance Chart. When you service your machine, use only high quality lubricants.

TRIP

ODO

12345.6

1/10H

AUTO

n n/min

A27274

Figure 7

Ask your dealer about our lubr icant analysis program, Systemgard®. Through this service, your lubricants are tested in an independent laboratory.

You simply remove a sample of lubricant from your machine and send the sample to the independent System gard ® lab orator y. After the sam ple is processed, the laboratory will report back to you and g u i d e yo u w i t h m a i n t e n a n c e r e q u i r e m e n t s .

Systemgard® can help support your equipment up time and provide you with a service that can pay back dividends when you trade for another piece of equipment.

The normal engine oil change interval is every 500 hours of operation. Operating conditions, quality of the engine oil and sulphur content of the fuel can change this interval. It is recommended that you use the Systemgard ® Lubricant Analysis program. See your dealer.

PLASTIC AND RESIN PARTS Avoid using gasoline, kerosene, paint thinner, etc., when cleaning plastic windows, console, instrument cluster, monitor, gauges, etc. Use ONLY water, mild soap and a soft cloth when you clean these parts.

Using gasoline, kerosene, thinners, etc., will cause discoloration, cracking or deformation of the part being cleaned.

5-6

CT06M013

TRIP

Figure 8

The engine hourmeter shows the amount of actual hours the engine has run. The first number to the right displays tenths of an hour and the numbers to the left display hours. Use the engine hourmeter along with the Lubrication/Maintenance Chart to service your machine at the correct time periods.

Engine hours are displayed with the key switch off or with the engine running.

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

FLUIDS AND LUBRICANTS ENGINE CRANKCASE Capacity with Filter Change ...................................................................................................... 18 Qts. (17 Liters) Specifications ...................................................................................................................... CASE AKCELA No. 1 FUEL TANK Capacity ...................................................................................................................................79 gal. (300 Liters) COOLING SYSTEM Capacity ................................................................................................................................. 15.9 Qts. (15 Liters) Specifications ............................................................................................. 50% Water and 50% Ethylene Glycol NOTE: If the ambient temperature is lower than -37°C (-34°F), adjust the mixture according to the coolant manufacturer specifications.

HYDRAULIC RESERVOIR/TRANSMISSION REFILL Total system capacity ................................................................................................................44 gal. (165 Liters) Reservoir capacity.......................................................................................................................24 gal. (90 Liters) Specifications ...................................................................................................................... CASE Hydraulic Fluid TRAVEL REDUCTION GEARS Capacity - (per reduction gear) ................................................................................................ 4.8 Qts. (4.5 Liters) Specifications ................................................................................................................................. Case 135 H EP SWING REDUCTION GEARS Capacity (per reduction gear)...................................................................................................... 5.3 Qts. (5 Liters) Specifications ............................................................................................................................... Case 135 H EP

5-7

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART

6-12 As Required (AR)

Every 10 hours

Air filter

AR

AR

Fuel tank screen

AR

AR

6-3

Clean track

6-5

Steel track shoe bolt torque

AR

5-13

Engine oil level

10

5-13

Coolant level

10

5-15

Radiator and oil cooler

10

5-14

Fan/alternator belt tension

10

5-15

Hydraulic reservoir level

10

5-16

Fuel pre-filter purge

5-16

Bleed fuel filters

5-17

Hydraulic system lines

5-17

Pilot filter

Run-in

50

5-18

Return filter

Run-in

50

AR

10 10 50

Air conditioning

50

6-5

Track shoe bolt torque

Run-in

50

6-15

Bolt and nut torque

Run-in

50

7-4

Battery check

50

5-19

Drain hydraulic reservoir sediment

5-20

Swing reduction gear

Run-in

250

5-21

Travel reduction gears

Run-in

250

5-22

Fuel prefilter

5-23

Air filter dust ejector

5-23

Bucket pins and attachment

6-5

Track shoe bolt torque

250

6-15

Bolt and nut torque

250

7-5

Battery electrolyte level

250

6-6

Fan/alternator belt tension

250

6-4

Idler wheel and roller

250

5-24

Machine grease points

500

5-24

Turntable bearing

500

5-24

Turntable teeth

500

5-25

DRAIN

GREASE

REPLACE

CHECK AR

6-7

Every 500 hours 5-25

5-8

Fan and air conditioning drive belt

5-23

Every 50 hours 6-12

Every 250 hours

CLEAN

PAGE

SERVICE POINTS

INITIAL NEW MACHINE

Intervals In Hours SERVICE INTERVALS

250

250 250 250

Engine oil

500

Engine oil filters

500

5-26

Fuel filter

5-27

Priming pump

500

500

6-5

Radiator and oil cooler

500

6-6

Fan and alternator belt tension

500

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

Every 1000 hours

5-28

Machine arm and attachments

5-30

Air filter primary and secondary

Every 4000 hours

Every 5000 hours

DRAIN

GREASE

REPLACE

CHECK

1000 1000

5-32

Draining and filling cooling system

5-34

Hydraulic fluid condition

5-35

Swing reduction gear

1000

5-36

Breather filter

1000

5-37

Travel reduction Gear

See your Case Dealer

Every 2000 hours

CLEAN

PAGE

SERVICE POINTS

INITIAL NEW MACHINE

Intervals In Hours SERVICE INTERVALS

1000 1000

1000

Tappet clearances

1000

Alternator

1000

Starter motor

1000

5-38

Inlet filter

5-39

Return filter

2000 2000

5-40

Pilot filter

2000

5-40

Swing reduction gear

See your Case Dealer

Fuel hoses

4000

Main pump output hydraulic hoses

4000

Boom/bucket cylinder hydraulic hoses

4000

5-41

Hydraulic fluid

5000

5-42

Replacing inlet filter

5000

6-14

Air conditioning filters

5000

2000

NOTE: Due to operating conditions, the service intervals may need to be shortened to provide maximum machine performance and protection.

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. See “Systems Display and Control Panel” in the “Controls/Instruments/Accessories” Section.

5-9

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

ENGINE LUBRICATION ENGINE OIL SELECTION API Service CI-4 Engine Oil is recommended for use in your Case Engine. Case AKCELA No. 1 Engine Oil will lubricate your engine correctly under all operating conditions.

If Case oil is not available, use only oil meeting API engine oil standards.

See the chart below for recommended viscosity at ambient air temperature ranges.

NOTE: Do not put performance additives or other oil additive products in the engine crankcase. The oil change intervals given in this manual are according to tests with Case lubricants.

BD97F136

Figure 9

NOTE: Use of an engine oil pan heater or an engine coolant heater may be required when operating in Winter or Arctic conditions.

NOTE: The use of low viscosity oils, such as 10W-30 can be used to aid in starting the engine and in providing sufficient oil flow at ambient temperatures below -5°C (23°F). The continuous use of low viscosity oils can decrease engine life due to wear.

See the chart below for the correct oil for ambient temperatures.

OIL VISCOSITY/TEMPERATURE RANGES

BC02N250

5-10

Figure 10

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS FLUIDS AND LUBRICANTS Lubricants must have the correct properties for each application. Adhere to machine lubrication intervals specified by the manufacturer.

TRANSMISSION COMPONENT OIL

HYDRAULIC FLUID

CASE/AKCELA: GEAR 135H EP

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

(SAE 80W-90. API GL 5. MIL-L-2105 D. MAT 3506 ZF TE-ML 05A)

Temperate Climates

CASE/AKCELA: MAT 3550 MOLY GREASE 251H EP-M (NLGI 2)

-20°C to +40°C CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID (MAT 3509 ISO VG 46. DIN 51524 PART 2 HV) Hot Climates 0° C to +50° C

Extreme pressure oil used for enclosed transmission components.

GREASE

“Extreme Pressure” multipurpose grease with lithium soap and molybdenum dissuasively.

C A S E / A K C E L A : M AT 3 5 5 0 M ULT IP U R P O S E GREASE 251H EP (NLGI 2)

CASE/AKCELA: AW HYDRAULIC FLUID 68 HV

“Extreme Pressure” multipurpose grease with lithium soap and calcium.

( M AT 3 5 0 8 I S O VG 6 8 . D I N 5 1 5 2 4 PA RT 3 CATEGORY HVLP)

CASE/AKCELA: MAT 3550 PREMIUM GREASE EP2 (NLGI 2)

Cold Climates

“Extreme Pressure” multipurpose grease with lithium soap.

-25° C to +20° C CASE/AKCELA: AW HYDRAULIC FLUID 32 (MAT 3508 ISO VG 32. DIN 51524 PART 2)

Hydraulic Breakers CA SE / A K C E L A : M AT 3 5 5 0 M U LT I PU RP O S E GREASE 251H EP (NLGI 2).

Biodegradable Fluid: -30° C to +40° C This yellow-colored fluid is miscible with standard fluid. If used to change standard fluid, it is advisable to drain the circuit completely before refilling with this fluid.

CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID BIO (MAT 3509 ISO VG 46. DIN 51524 PART 2 HV)

5-11

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS DAILY/PERIODIC INSPECTION Every day, before starting work, it is necessary to inspect the machine and service certain of its components.

General

• • • •

Check for signs of leaking oil or water.

Check that all screws and nuts are correctly tightened.

Wipe off any dust (engine, operator’s compartment, decals and warning labels).

Check for any signs of deterioration.

Engine

• • • • • • •

Check the oil level, and change the oil if necessary.

Check the coolant level.

Check the radiator for signs of clogging or deterioration of air flow.

Check the radiator fan belt tension.

Check the air filter for cleanliness and/or restrictions.

Check the components for signs of leaking oil or water.

Check the condition of all lines and tubes.

Upper Structure

• • • • • • • •

Check the fuel tank level.

Check the hydraulic reservoir level.

Check that the hydraulic oil is clean.

Check the components for signs of leaking oil or water.

Check the condition of all lines.

Make sure there are no electrical short circuits.

Check the battery connections are properly tightened.

Adjust the rear view mirrors.

Undercarriage

• Check the pad and pad hardware.

• Check the condition of the track chain assembly.

• Check that the upper and lower track rollers and the idler wheels are not leaking oil.

Attachment

• • • •

Check the cylinders are not leaking oil.

Check the condition of all lines and tubes.

Check the condition of the bucket teeth.

Check the attachment for any damage or deterioration.

After Starting The Engine

• • • • • •

Did the engine start correctly? Are the exhaust fumes normal? Any strange noises?

Check that the hydraulic components are not making strange noises.

Check the components for signs of leaking oil or water.

Check the audible alarm devices, working lights and windshield wipers.

Check that all circuits (travel, swing and tool) are functioning correctly.

Check that the upper structure swing brake functions correctly.

IMPORTANT: If any defect is found, repair it immediately prior to using the machine or contact your dealer.

5-12

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 10 HOUR MAINTENANCE ENGINE OIL LEVEL

CHECK COOLANT LEVEL

Perform the following procedures daily or at every ten hour shift.

Service Specifications System capacity . . . . . . . . . . . . . 15.9 Qts (15 Liters)

Service Specifications Oil Type . . . . . . . . . . . . . . . . . . CASE AKCELA No. 1 Oil Capacity with filter . . . . . . . . . . 18 Qts. (17 Liters)

Check the coolant level before you start the engine each day or before the start of each 10 hour shift.

Check the engine oil level before you start the engine each day or before the start of each 10 hour shift.

Always check the oil level with the engine stopped and with the machine on firm, level ground.

WARNING

Push the engine oil level dipstick completely down, and pull out before you check the oil level.

If the oil level is below the ADD mark (A), add oil to raise the oil level up to the FULL mark (B).

Hot liquid under pressure! Never remove the filler cap or the recovery tank cap while the engine is running or the coolant is hot. Let the system cool.

Turn the filler cap to the first notch and allow any pressure to escape, and then remove the filler cap.

Loosen the recovery tank cap slowly to allow any pressure to escape. Failure to comply could result in death or serious injury.

WO296A

WARNING

2

Always remove the recovery tank cap BEFORE you remove the filler cap. Never remove either cap while the engine is running or the coolant is hot. Stop the engine and let the system cool. Using a thick cloth, loosen the cap slowly and allow the pressure to escape. Failure to comply could result in death or serious injury

1

WO198A

Figure 11

CT07A079

1. ENGINE OIL DIPSTICK 2. ENGINE OIL FILL

A

B CT05L023

Figure 12

The oil level should be between the marks (A) and (B) on the dipstick.

NOTE: The level should not be higher than the mark (B) maximum on the dipstick.

5-13

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS Coolant Solution Put only ethylene-glycol coolant solution in the cooling system. Use good quality ethylene-glycol that has a high boiling point with no additives to prevent l e a k a g e. D o n o t u s e n o n - a p p r ove d a n t i - r u s t additives. Anti-rust additives and ethylene-glycol can m i x a n d w o r k a g a i n s t e a c h o t h e r, r e d u c i n g anti-corrosion, and causing damage to the cooling system and radiator.

Consult your CASE Dealer for suitable coolant solution.

The level of coolant solution should be checked when the engine is cold.

1

2 CT07A080

Figure 13

On flat, level ground, before using the machine, (while the engine is still cold), the level in the coolant reservoir should be between the “FULL” (1) and “LOW” (2) marks.

5-14

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 10 HOUR MAINTENANCE

FAN AND ALTERNATOR DRIVE BELT

RADIATOR AND OIL COOLER

Visually check the fan and alternator drive belt before you start the engine each day or before the start of each 10 hour shift.

Check the radiator and oil cooler before you start the engine each day or before the start of each 10 hour shift.

CT07A098

CT07A086

Figure 14

CT07A064

Figure 15

Figure 16

Check for any signs of wear or 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.

Check for leakage on and around the radiator and oil cooler components.

5-15

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 10 HOUR MAINTENANCE HYDRAULIC FLUID RESERVOIR LEVEL Service Specifications Reservoir capacity . . . . . . . . . . . . 24 Gal. (90 Liters)

1. Keep all non-authorized personnel clear of the area. Start and position the machine on firm, level ground, and place the attachment in the position shown. Stop the engine, and remove the starter switch key.

Total system capacity . . . . . . . . 44 Gal. (165 Liters) Check the hydraulic fluid reservoir level before you start the engine each day or before the start of each 10 hour shift. Always check levels with the engine stopped and with the machine on firm, level ground.

IMPORTANT: After replacing the hydraulic fluid, it is necessary to bleed all air from the hydraulic components. See “Bleeding Air from the Hydraulic Components”.

WARNING Before performing any service on the hydraulic system, you must allow it to cool. Hydraulic fluid temperature should not exceed 40 °C (104 °F).

Failure to comply could result in death or serious injury.

Figure 18

CT07A081

2. The oil should be in the middle of the indicator.

Add more oil if necessary.

WARNING

WO241A

WARNING Pressurized hydraulic fluid can penetrate the skin and cause severe injuries.

Hydraulic fluid is under extreme pressure. Rest the bucket or attachment on the ground. Shut the engine off, turn the key on, and move the hydraulic control lever through all movements several times to relieve residual pressure in the system.. Failure to comply could result in death or serious injury.

WO016A

Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition.

Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury.

WO178A

Check Hydraulic Fluid Level In The Reservoir

CS98N547

5-16

Figure 17

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS Filling The Reservoir 1. Release all pressure in the hydraulic reservoir.

See “Releasing Pressure in the Hydraulic System.”

CT06K102

Figure 19

2. Clean the cover plate and the area around the plate.

3. Remove the cover plate and add hydraulic fluid to the reservoir as required.

4. Replace the cover plate seal, and install the cover plate.

5-17

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 10 HOUR MAINTENANCE

FUEL FILTER BLEEDING

FUEL PREFILTER BLEEDING

Bleed the fuel filter before you start the engine each day or before the start of each 10 hour shift.

Check and drain the fuel prefilter before you start the engine each day or before the start of a 10 hour shift.

CT07A090 CT07A081

Figure 20

1. The fuel prefilter and fuel filter are located behind the right rear access door. Place a receptacle of a suitable capacity under the prefilter. Loosen the drain plug and drain the water and dirty fuel.

1. Place a container with a suitable capacity under the filter.

CT07A090

CT07A081

Figure 21

Figure 22

Figure 23

2. Loosen the drain plug and drain the water and dirty fuel. After draining, retighten the bleed screw.

2. After draining, close the drain plug. Check for any signs of leakage.

FUEL TANK SCREEN

CT07A099

Figure 24

The fuel tank screen is located in the fuel tank orifice.

Clean the tank screen periodically. To clean, remove cap and filter. Clean the screen in diesel oil.

5-18

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 50 HOUR MAINTENANCE HYDRAULIC SYSTEM LINES

PILOT FILTER REPLACEMENT

Check hydraulic system lines when the machine is new at the initial 50 hour run-in period.

Service Specifications Reservoir capacity . . . . . . . . . . . . .24 Gal. (90 Liters) Total system capacity . . . . . . . . .44 Gal. (165 Liters) IMPORTANT: After replacing the hydraulic fluid, it is necessary to bleed all air from the hydraulic components. See “Bleeding Air from the Hydraulic Components” at the beginning of this section.

WARNING Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition.

Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury.

Figure 25

CT06K088

PILOT FILTER LOCATION

Replace the pilot filter when the machine hour meter registers 50 hours during the initial run-in period. The pilot filter will be replaced at 2000 hours thereafter, or sooner if conditions so require.

1. Keep all non-essential personnel clear of the area. Release all pressure in the hydraulic system. See “Releasing Pressure in the Hydraulic System.”

WO178A

1

WARNING 2

Hydraulic fluid can also infect a minor cut or opening in the skin. Serious infection or reaction can result without immediate medical treatment. If injured by leaking fluid, see your doctor immediately Failure to comply could result in death or serious injury.

3 4

WO358A

CS98M619

Figure 26

2. Use a wrench on the bottom of the filter body (4) to unscrew and remove it.

3. Remove the old filter (3) and the O-ring (2).

4. Clean the filter body (4) in solvent and wipe dry with a cloth.

5. Coat the new filter (3) and the new O-ring (2) with clean hydraulic fluid. Install the new filter on the head (1).

6. Install the filter body (4) and tighten until seal comes into contact with the filter head then tighten an extra third of a turn by hand. Do not overtighten.

5-19

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 50 HOUR MAINTENANCE RETURN FILTER REPLACEMENT

1

Replace the hydraulic return filter when the machine is new and the hour meter registers 50 hours.

Replace the hydraulic fluid return filter when the hour meter registers every 2000 hours thereafter or sooner if conditions so require.

2

3

1. Keep all non-essential personnel clear of the area. Release all pressure in the hydraulic reser voir. See “Releasing Pressure in the Hydraulic System.” Clean the top of the hydraulic reservoir and clean the return filter cover.

4

5

CT06K103

Figure 27

2. Remove the upper plate (1) on the hydraulic reservoir.

3. Clean the top of the hydraulic reservoir and clean the return filter cover.

CT07A049

Figure 28

4. Remove the cover (1) and O-ring (2).

5. Take out the spring (3), valve (4) and return filter (5).

6. Install a new filter. Clean the spring (3) and valve (4) and assemble them.

7. Check O-ring (2), and replace it if worn or damaged.

8. Install the cover (1).

9. Check the level of the hydraulic fluid and add more fl uid, if necessar y. See “Filling the Reservoir”.

5-20

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE DRAINING WATER AND SEDIMENT FROM THE HYDRAULIC RESERVOIR Drain the hydraulic reservoir when the machine hour meter registers 250 hours or more often if conditions so require.

CT06M029

Figure 29

1. Keep all non-essential personnel clear of the area. Release all pressure in the hydraulic reser voir. See “Releasing Pressure in the Hydraulic System.”

2. Position a receptacle of suitable capacity under the drain plug.

3. Loosen the drain plug on the bottom of the reservoir, and drain the sediment and water accumulated at the bottom of the reservoir.

4. After draining, tighten the drain plug. Add hydraulic oil if necessary.

5-21

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE SWING REDUCTION GEAR Service Specifications Oil capacity . . . . . . . . . . . . . . . . . . 5.3 Qts (5 Liters) Oil type . . . . . . . . . . . . . . . . . . . . . . . . Case 135H EP (per reduction gear)

DRAINING AND REFILLING SWING REDUCTION GEAR OIL

3

Perform an oil change after the first 250 hours of operation during run-in. Check swing reduction gear oil level every 250 hours thereafter. An oil change is also required at each 1000 hour interval thereafter.

2 1 CT07A095

Figure 31

1. Keep all non-essential personnel clear of the area. Park the machine on flat, level ground.

Stop the engine, and remove the starter switch key.

2. Remove the dipstick (1) and the filler plug (2).

CT07A083

Figure 30

3. Place a receptacle of a suitable capacity under the upper structure, and remove the drain plug (3).

1. Keep all non-authorized personnel clear of the machine. Park the machine on firm, level ground.

Stop the engine and remove the starter switch key.

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

2. To check the oil level, remove the dipstick (1).

The oil should come up to the hatched area. Add oil if necessary through the filler hole (2).

IMPORTANT: Check the condition of the drained oil.

If it contains metal filings or foreign matter, see your CASE Dealer.

3. Install the dipstick.

4. Allow the oil to drain.

5. Install the drain plug (3).

6. Add oil through the filler holes (2) until the level is correct.

7. Install the dipstick (1) and the filler plugs (2).

8. Wait ten minutes and check the oil level again.

Add more oil, if necessary.

5-22

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE Draining And Refilling Travel Reduction Gears

TRAVEL REDUCTION GEARS Service Specifications Oil capacity . . . . . . . . . . . . . . . . . 4.8 Qts (4.5 Liters) (per reduction gear) Oil type . . . . . . . . . . . . . . . . . . . . . . .Case 135 H EP (per reduction gear) 1. Change the travel reduction gear oil after the first 25 0 ho ur s o f op e ra ti o n . C h eck t he trave l reduction gear oil every 250 hours thereafter. An oil change is also required at each 1000 hour interval.

1. Park the machine on flat, level ground.

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

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

4. Place a receptacle of a suitable capacity under the travel reduction gear and remove plugs (1) and (2).

5. Allow the oil to drain.

IMPORTANT: Check the condition of the drained oil.

If it contains metal filings or foreign matter, see your CASE Dealer.

3

6. Install plug (1), fill with oil through the orifice (3) until oil comes up to the bottom edge of port (2).

2

7. Install plug (2) and repeat the procedure for the other travel reduction gear.

8. Travel slowly with the machine, and make certain there are no leaks.

1

CD01K025

Figure 32

2. Keep all non-authorized personnel clear of the area. Park the machine on flat, level ground.

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

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

5. Slowly loosen the plug (3) to release any residual pressure.

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

7. Install the plugs.

8. Repeat for the other travel reduction gear.

9. Travel slowly with the machine and make certain there are no leaks.

5-23

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE REPLACE THE FUEL PREFILTER Replace the fuel prefilter when the machine hour meter registers 250 hours or more often if conditions so require.

4

1 Figure 35

CT07A089

6. Clean the area around the sediment bowl (4), then remove the bowl from the filtering element by loosening it using the wrench provided with the machine.

Figure 33

CT07A088

1. Filters are located behind the right engine access door.

2. Place a receptacle of a suitable capacity under the prefilter.

7. Clean the sediment bowl (4). Check the condition of its seal and replace if the seal is damaged.

Apply a thin coat of oil on the new seal. Install the sediment bowl on a new filter element.

NOTE: Only the filter element must be replaced, not the sediment bowl.

3. Close the valve on the supply line (1).

3

5

2

CT07A089 CT07A081

Figure 34

4. Loosen the bleed plug (2) and the plug (3). Allow the prefilter to drain.

5. Clean around the prefilter body. Remove the prefilter using the filter wrench provided with the machine.

Figure 36

8. Reinstall the assembly on the filter head by rotating the prefilter until the seal is in contact with the filter head (5). Tighten the body to a torque of 20 ft lbs to 23 ft lbs (27.5 to 31.3 Nm).

Do not over tighten. Retighten the bleed plug (2).

9. Bleed the system.

NOTE: In cold weather, the water can freeze on the top part of the bowl. Bleed after ice has melted.

5-24

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 250 HOUR MAINTENANCE AIR FILTER

ARM/ATTACHMENT GREASE POINTS

Inspection

Service Specifications EP NLGI grade 2 MAT 3550 . . . . . (for temperate and hot climates) -20° C to +60° C (-4° to 160° F) EP NLGI grade 0 MAT 3550 . . . . . . . (for cold climates) -40° C to +20° C (-40° to 68° F)

Be sure to carry out regular checks on the air filter, intake manifold, seals and hoses. At the same time, check the intake manifold screws and hose clamps for tightness.

The hoses should be replaced before they are worn.

Dust Ejector

Grease the following points every 250 hours or sooner if conditions so require. If linkage is not fitted with genuine CASE parts, grease every 10 hours.

1 2 CT07A092

Figure 37

Periodically check the dust injector. Replace the primary air filter element every 1000 hours. The secondary element should be replaced at the same time. Do not clean the secondary element. It must be replaced. Replacing the air filter elements may be requi red mo r e f r eq u e nt l y i n ex tr e m el y d u sty conditions.

BD00J052

Figure 38

(1) Boom Pivot Pin . . . . . . . . . . . . . . . . . (2 locations) (2) Arm Connecting Pin . . . . . . . . . . . . . (2 locations)

If the air restriction message displays and/or the audible alarm device sounds, shut the engine off and find the cause of the problem.

Additionally, an indicator is located next to the air filter. This indicator shows the state of the air filter elements. When the central zone of the indicator becomes red then the elements must be serviced, irrespective of the next scheduled service interval.

Once the elements have been serviced, press the button on top of the indicator to start a new indication cycle.

5-25

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 500 HOUR MAINTENANCE Perform the following when the machine hour meter registers 500 hours or warning gauges so indicate.

GREASING THE TURNTABLE TEETH

MACHINE GREASE POINTS Use the following grease: EP NLGI grade 2 MAT 3550 . . . . . (for temperate and hot climates) -20° C to +60° C (-4° to 160° F) EP NLGI grade 0 MAT 3550 . . . . . (for cold climates) -40° C to +20° C (-40° to 68° F)

1

Figure 42

CD01K065

1 2 2

Figure 39

CS98N551

1 CD01L028

Figure 43

1. Every 500 hours, remove the inspection cover (1) and visually check the condition of the gear surface for any damage.

2. If the gear surface is not well greased, add grease.

3. If the grease is white due to moisture content, etc. replace it with new grease.

Figure 40

CT07A074

Turntable bearing . . . . . . . . . . . . . . . . . . (2 locations)

2

4. If the presence of water is detected: A. Remove the protective panel from the lower, central area.

B. Remove the plug (2).

C. Discharge the water or cloudy grease.

D. Install plug (2).

E. Insert new grease through the port and install the cover (1).

1

CD010034

Figure 41

Turntable teeth . . . . . . . . . . . . . . . . . . . . . (1 location) 5-26

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 500 HOUR MAINTENANCE OIL CHANGE AND FILTER REPLACEMENT Service Specifications Oil Type . . . . . . . . . . . . . . . . . . CASE AKCELA No. 1 Oil Capacity with filter . . . . . . . . . . 18 Qts. (17 Liters) Change the engine oil more frequently than every 500 hours when the engine operating conditions are severe (frequent stopping and starting and high or low engine temperatures).

1. Park the machine on a flat, level area. Stop the engine, and remove the starter key. Oil will be easier to change if it is still warm (not hot). Before draining the oil, have a container that will hold the required oil quantity.

3 CT07A090

Figure 46

6. Clean the area around the filter (3) and remove it.

1

Figure 44

CT07A079

PH08325

2. Remove the oil filter cap (1).

Figure 47

7. To replace the filter, coat the seal of the new filter with a fine film of oil.

8. Install the new filter. Turn the filter until the seal comes into contact with the filter head, and turn an extra half turn by hand.

2

IMPORTANT: Do not use a filter wrench to tighten the filter. Excessive tightening can damage the filter and their seals.

9. Fill the engine with new engine oil. Install the oil filler cap.

CT07A084

Figure 45

3. Remove the protective cap (2) from the engine housing drain.

4. Screw the end of the extension drain hose provided with the machine onto the engine check valve. Place the other end in a container of suitable capacity and allow the oil to drain.

5. Remove the extension drain hose and install the protective cap on the housing check valve.

Return the extension drain hose to its storage compartment.

10. Run the engine for a few minutes, and make certain there are no leaks. Check the oil level again, and add more oil if necessary.

IMPORTANT: You must shorten the oil change interval if you use diesel fuel with a sulphur content of more than 0.5%.

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

5-27

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 500 HOUR MAINTENANCE REPLACING THE FUEL FILTER Replace the fuel filter when the hour meter registers 500 hours or more often if conditions require

1 CT06M016

CT07A088

Figure 48

1. Filters are located behind the right engine access door.

2. Place a receptacle of a suitable capacity under the prefilter.

3. Close the valve on the supply line (1).

Figure 50

7. Install the new filter. Turn the filter until the seal comes into contact with the filter head. Tighten the body to a torque of 20 ft lbs to 23 ft lbs (27.5 to 31.3 Nm). Do not over tighten. Retighten the bleed plug (2).

8. Bleed the system.

IMPORTANT: Do not use a filter wrench to install the filter. Overtightening the filter can damage the seal and filter.

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

CT07A090

Figure 49

4. Clean the area around the filter head.

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

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

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

5-28

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 500 HOUR MAINTENANCE

WARNING

BLEEDING THE SYSTEM It is necessary to bleed the fuel system when:

• The tank has been completely emptied.

• The fuel filter has been replaced.

• Parts of the fuel system have been removed for service or repair.

Fuel vapors are explosive and flammable. Do not smoke while handling fuel. Keep fuel away from flames or sparks. Shut off engine and remove key before servicing. Always work in a well-ventilated area. Clean up spilled fuel immediately. Failure to comply could result in death or serious injury.

WO904A

• The machine has been in storage.

1

2

CT07A085

Figure 51

To Bleed The System: 1. Loosen the knob of the priming pump (2).

Loosen the air bleed screw (1). Turn the starter switch key to the “ON” position. Turn the priming pump handle (2) to the left in order to release the spring.

2. Move the handle of the priming pump (2) up and down until no bubbles come out of the air bleed screw (1).

3. When bubbles no longer come out, tighten the air bleed screw (1) and tighten the knob of the priming pump (2). Completely wipe off any spilled fuel. Start the engine, and check for fuel leakage.

4. Fuel vapors are explosive and flammable.

5. Do not smoke while handling fuel. Keep fuel away from flames or sparks. Shut off engine and remove key before servicing. Always work in a well-ventilated area. Clean up spilled fuel immediately.

5-29

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE Perform the following when the machine hour meter registers 1000 hours.

ARM AND ATTACHMENT GREASE POINTS Use the following grease: EP NLGI grade 2 (MAT 3550) - for temperate and hot climates - 20° C to +60° C (-4° to 160° F) EP NLGI grade 0 (MAT 3550) for cold climates - 40° C to +20° C (-40° to 68° F)

1

1

2

6 5 3 5

Figure 52

CS98N551

3

1

CT07A077

4

Figure 53

Boom bottom pin . . . . . . . . . . . . . . . . . . (2 locations) Boom cylinder top pin . . . . . . . . . . . . . . . (2 locations) Arm cylinder bottom pin . . . . . . . . . . . . . . (1 location)

CD01D038

Figure 54

Boom arm linkage . . . . . . . . . . . . . . . . . (2 locations)

4 2

CT06K094

Attachment cylinder bottom pin . . . . . . . . (1 location)

CD01N022 BD00J052

Arm cylinder top pin . . . . . . . . . . . . . . . . . (1 location) 5-30

Figure 55

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE

5

A

CT06K094

Figure 56

Connecting rod linkage . . . . . . . . . . . . . (7 locations) A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(1 each side)

6

CT07A075

Figure 57

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

5-31

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE AIR FILTER

Removing The Elements

Inspection Be sure to carry out regular checks on the air filter, intake manifold, seals and hoses. At the same time, check the intake manifold screws and hose clamps for tightness.

The hoses should be replaced before they are worn.

CT07A092

Figure 59

1. Release the fasteners and remove the cover.

CT07A092

Figure 58

Replace the primary element every 1000 hours. The secondary element should be replaced at the same time. Do not clean the secondary element. It must be replaced. Replacing the air filter elements may be required more frequently in ex tr emel y dusty conditions.

If the air restriction message displays and/or the audible alarm device sounds, shut the engine off and find the cause of the problem.

CT07A093

Figure 60

2. Remove the primary element.

Additionally, an indicator is located next to the air filter. This indicator shows the state of the air filter elements. When the central zone of the indicator becomes red then the elements must be serviced, irrespective of the next scheduled service interval.

Once the elements have been serviced, press the button on top of the indicator to start a new indication cycle.

Observe the air filter service intervals, as clean filters mean longer engine life.

CT07A094

Figure 61

3. Remove the secondary element by loosening the wing nut. The secondary element should be replaced at the same time the primary element is replaced.

IMPORTANT: Do not clean the secondary element. It must be changed, not cleaned.

5-32

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE Installing The Air Filter Elements

CD01N017 CT07A094

Figure 62

1. Install the new secondary element and tighten the wing nut.

Figure 64

3. Install the cover and fasten in place. Make certain the word “Top” is at the top with arrows pointing up.

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

CT06K107

Figure 63

2. Install the new primary element

5-33

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE DRAINING AND FILLING THE COOLING SYSTEM

Draining

Service Specifications System capacity . . . . . . . . . . . . . 15.9 Qts. (15 Liters) Type . . . . . . . . .50% water and 50% Ethylene Glycol Drain the engine coolant when the hour meter registers 1000 hours, flush the system, and refill with new coolant. If the low coolant or overheat message displays and/or the audible alarm device sounds, shut the engine off, and find the cause of the problem.

WARNING Take care if removing the filler cap while the system is hot. Before removing the cap: completely cover the cap using a thick cloth, and slowly open the filler cap to allow the pressure to escape. Do not add cold water to a hot coolant reservoir. Failure to comply could result in death or serious injury.

CT07A086

Figure 65

1. Using the starter switch key, open the access hatch, then remove the radiator cap.

WO031A

WARNING Hot coolant can spray out if you remove the filler cap while the system is hot. After the system has cooled, turn the filler cap to the first notch and wait for all pressure to release before proceeding Failure to comply could result in death or serious injury.

WO043A

Coolant solution Put only ethylene-glycol coolant solution in the cooling system. Use good quality ethylene-glycol that has a high boiling point, with no additives to prevent l e a k a g e. D o n o t u s e n o n - a p p r ove d a n t i - r u s t additives. Anti-rust additives and ethylene-glycol can m i x a n d w o r k a g a i n s t e a c h o t h e r, r e d u c i n g anti-corrosion protection, forming deposits in the cooling system, and causing damage to the cooling system and radiator.

CT06M027

Figure 66

2. Have a receptacle of suitable capacity ready.

Open the radiator drain valve.

Consult your CASE Dealer for suitable coolant solution.

Coolant Level The level of coolant solution should be checked when the engine is cold.

On firm, level ground, before using the machine (while the engine is still cold), the level in the expansion reservoir should be between the “Full” (1) and “Low” (2) marks. If not, see “Filling”.

5-34

CT06M028

Figure 67

3. Open the drain plug located on the engine block and drain into a receptacle of suitable capacity.

Allow the radiator to completely empty.

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE Flushing

Filling

1. Close the drain valve once the radiator is completely empty. Close the plug on the engine block.

2. Fill the system with clean water. Install the radiator cap.

3. Keep all non-authorized personnel clear of the machine. Start the engine. Run the engine at a speed slightly higher than idle speed for ten minutes to bring the engine temperature up to about 80°C (176° F).

4. Drain the system once more.

5. Repeat Steps 1 to 4 until the water drained is clear.

WARNING

CT07A086

Figure 68

1. Fill with coolant solution via the radiator until it overflows, install the radiator cap then lock the access hatch.

Hot coolant can spray out if you remove the filler cap while the system is hot. After the system has cooled, turn the filler cap to the first notch and wait for all pressure to release before proceedingFailure to comply could result in death or serious injury.

WO043A

CT07A080

Figure 69

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.

5-35

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE HYDRAULIC SYSTEM Service Specifications Reservoir capacity .......................................................................................................................... 24 Gal. (90 Liters) Total system capacity .................................................................................................................. 44 Gal. (165 Liters) Type of oil ............................................................................................................... Case Hy-Tran Ultra® (MAT 3505) NOTE: If the machine is new or if a major part has been overhauled or replaced in the hydraulic system, replace the pilot filter and return filter after 50 hours of operation. After that, replace these filters at the stipulated interval.

IMPORTANT: Every 1000 operating hours, it is necessary to have the hydraulic fluid analyzed. See your CASE Dealer.

IMPORTANT: After replacing the hydraulic fluid, it is necessary to bleed all air from the hydraulic components. See “Bleeding air from the hydraulic components” at the beginning of this section.

IMPORTANT: If metal filings are discovered in the replaced filters, see your CASE Dealer.

WARNING Pressurized hydraulic fluid can penetrate the skin and cause severe injuries. Hydraulic fluid is under extreme pressure. Rest the bucket or attachment on the ground. Shut the engine off, turn the key on, and move the hydraulic control lever through all movements several times to relieve residual pressure in the system. Failure to comply could result in injury or death.

WO161A

WARNING Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition.

Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in injury or death.

W0178A

5-36

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE Draining And Refilling

SWING REDUCTION GEAR Drain and refill the swing reduction gear oil when the hour meter registers 1000 hours.

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

Service Specifications Oil capacity . . . . . . . . . . . . . . . . . . .5.3 Qts (5 Liters) Oil type . . . . . . . . . . . . . . . . . . . . . . . Case 135H EP (per reduction gear)

2. Remove the dipstick (1) and the filler plug (2).

Level 1. Keep all non-essential personnel clear of the area. Park the machine on flat, level ground.

Stop the engine and remove the starter switch key.

3 2 CT06M30

Figure 71

3. Place a receptacle of a suitable capacity under the upper structure and remove the drain plug (3).

1

4. Allow the oil to drain.

NOTE: The oil will take a relatively long time to drain.

CT07A083

Figure 70

2. Remove the dipstick (1). The oil should come up to the hatched area. Add oil if necessary through the filler hole (2).

3. Install the dipstick.

IMPORTANT: Check the condition of the drained oil.

If it contains metal filings or foreign matter, see your CASE Dealer.

5. Install the drain plug (3).

6. Add oil through the filler holes (2) until the level is correct.

7. Install the dipsticks (1) and the filler plugs (2).

8. Wait ten minutes, and check the oil level again.

Add more oil, if necessary.

5-37

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 1000 HOUR MAINTENANCE RESERVOIR BREATHER REPLACEMENT

1 2 3 5 4 CT06K102

Figure 72

1. Release all pressure in the hydraulic reservoir.

See “Releasing pressure in the hydraulic system.”

CS0E528

Figure 73

2. Press the button (1) to release pressure in the hydraulic reservoir.

3. Remove the nut (2) and the cover (3) from the breather.

4. Remove and discard the used filter (4).

5. Install a new element, making sure the seal (5) is facing upwards.

6. Install the assembly.

5-38

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS Draining And Refilling

1000 HOUR MAINTENANCE TRAVEL REDUCTION GEARS Service Specifications Oil capacity . . . . . . . . . . . . . . . . . 4.8 Qts. (4.5 Liters) (per reduction gear) Oil type . . . . . . . . . . . . . .See “Fluids and lubricants” Drain and refill the travel reduction gear oil when the hour meter registers 1000 hours or more often if conditions so require.

1. Keep all non-essential personnel clear of the area. Park the machine on flat, level ground.

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

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

4. Slowly loosen the plug (2) to release any residual pressure.

5. Place a receptacle of a suitable capacity under the travel reduction gear and remove plugs (1) and (3).

2

6. Allow the oil to drain.

IMPORTANT: Check the condition of the drained oil.

If it contains metal filings or foreign matter, see your CASE Dealer.

3

7. Install plug (1), fill with oil through the orifice (2) until oil comes up to the bottom edge of port (3).

1 CD00E074

Figure 74

8. Install plugs and repeat the procedure for the other travel reduction gear.

9. Travel slowly with the machine and make certain there are no leaks.

5-39

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 2000 HOUR MAINTENANCE Perform the following when the machine hour meter registers 2000 hours or warning gauges so indicate.

HYDRAULIC SYSTEM Service Specifications Reservoir capacity .......................................................................................................................... 24 Gal. (90 Liters) Total system capacity .................................................................................................................. 44 Gal. (165 Liters) Type of oil ............................................................................................................... Case Hy-Tran Ultra® (MAT 3505) IMPORTANT: If the machine is new or if a major part has been overhauled or replaced in the hydraulic system, replace the pilot filter and return filter after 50 hours of operation. After that, replace these filters at the stipulated interval.

IMPORTANT: After replacing the hydraulic fluid, it is necessary to bleed all air from the hydraulic components. See “Bleeding air from the hydraulic components”.

IMPORTANT: If metal filings are discovered in the replaced filters, see your CASE Dealer.

CLEANING THE INLET FILTER

1

1. Keep all non-essential personnel clear of the area. Release all pressure in the hydraulic reser voir. See “Releasing pressure in the hydraulic system.”

2 3

4

CT06K102

Figure 75

2. Clean the top of the hydraulic reservoir and the inlet filter cover.

5

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

4. Remove the inlet filter (5) and clean with solvent.

Dry completely and check for any damage. If there is any damage on the surface, replace with a new filter.

CT07A048

Figure 76

5. Install a new O-ring (2) and install the inlet filter (5), spring (3), and rod assembly (4).

6. Install the cover (1).

7. Check the level of the hydraulic fluid and add more if necessary. See “Filling the Reservoir”.

NOTE: Install a new inlet filter when the hydraulic oil is replaced.

5-40

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 2000 HOUR MAINTENANCE RETURN FILTER REPLACEMENT

1

Replace the retur n filter when the hour meter registers every 2000 hours or sooner if conditions so require.

2

3

1. Keep all non-essential personnel clear of the area. Release all pressure in the hydraulic reser voir. See “Releasing pressure in the hydraulic system.” Clean the top of the hydraulic reservoir and clean the return filter cover.

4

5

CT06K103

Figure 77

2. Remove the upper plate (1) on the hydraulic reservoir.

3. Clean the top of the hydraulic reservoir and clean the return filter cover.

CT07A049

Figure 78

4. Remove the cover (1) and O-ring (2).

5. Take out the spring (3), valve (4) and return filter (5).

6. Install a new filter. Clean the spring (3) and valve (4) and assemble them.

7. Check O-ring (2), and replace it if worn or damaged.

8. Install the cover (1).

9. Check the level of the hydraulic fluid and add more fl uid, if necessar y. See “Filling the reservoir”.

5-41

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS GREASE SWING REDUCTION GEAR

2000 HOUR MAINTENANCE PILOT FILTER REPLACEMENT

1

Figure 81

CT07A078

Figure 79

Grease the swing reduction gear every 2000 hours or sooner if conditions so require.

Replace the pilot filter when the machine hour meter registers 2000 hours or sooner if conditions so require.

Remove the lower panel, and remove the air bleed plug (1). Refill with grease through the grease point (2). A small amount of grease will run out from the air bleed plug (1).

CT07A056

PILOT FILTER LOCATION

1. Keep all non-essential personnel clear of the area. Release all pressure in the hydraulic system. See “Releasing pressure in the hydraulic system.”

IMPORTANT: When greasing, if the air bleed plug (1) is not removed, the inner seal will be damaged.

1

2

2 3 4 CT07A076

CS98M619

Figure 80

2. Use a wrench on the bottom of the filter body (4) to unscrew and remove it.

3. Remove the old filter (3) and the O-ring (2).

4. Clean the filter body (4) in solvent and wipe dry with a cloth.

5. Coat the new filter (3) and the new O-ring (2) with clean hydraulic fluid. Install the new filter on the head (1).

6. Install the filter body (4) and tighten until the seal comes into contact with the filter head. Tighten a n ex t r a t h i r d o f a t u r n by h a n d . D o n o t overtighten.

5-42

Figure 82

The grease point (2) is located on the upper structure frame, under the boom foot.

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 5000 HOUR MAINTENANCE Service Specifications Reservoir capacity .......................................................................................................................... 24 Gal. (90 Liters) Total system capacity .................................................................................................................. 44 Gal. (165 Liters) Type of oil ............................................................................................................... Case Hy-Tran Ultra® (MAT 3505) REPLACING THE HYDRAULIC FLUID 1. Keep all unauthorized personnel clear of the area. Release all pressure in the hydraulic reser voir. See “Releasing pressure in the hydraulic system.”

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. Start and run the engine with no load for approximately five minutes.

10. Move each control slowly several times to remove any air in the system.

11. Swing the upper structure evenly left to right two 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. Make sure there are no air bubbles in the hydraulic reservoir.

14.

CT06K102

Figure 83

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.

WARNING Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition.

Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury.

WO178A

WARNING CT06M029

Figure 84

4. Remove the drain plug to remove the remaining fluid from the reservoir.

5. Replace the inlet filter and the return filter. See “Cleaning and replacement of the inlet filter” and “Return filter replacement”.

6. Install the reservoir drain plug.

7. Put new hydraulic fluid into the reservoir. See “Filling the reservoir”.

8. Install the reservoir cover plate and seal.

Before performing any service on the hydraulic system, you must allow it to cool. Hydraulic fluid temperature should not exceed 40 °C (104 °F)..

Failure to comply could result in death or serious injury.

WO241A

WARNING The hydraulic tank is a pressurized system. Vent tank slowly by loosening the breather before performing work on the hydraulic system. Failure to comply could result in death or serious injury.

WO198A

5-43

CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 5000 HOUR MAINTENANCE REPLACEMENT OF THE INLET FILTER

1

Replace the hydraulic fluid inlet filter when the hour meter registers 5000 hours or sooner if conditions so require.

2

1. Keep all non-essential personnel clear of the area. Release all pressure in the hydraulic reser voir. See “Releasing pressure in the hydraulic system.”

3

4

5 CT06K102

Figure 85

2. Clean the top of the hydraulic reservoir and clean the inlet filter cover.

CT07A048

Figure 86

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

5. Install a new O-ring (2) and install the new inlet filter (5), spring (3) and rod assembly (4).

4. Remove the inlet filter (5), replace with a new filter.

6. Install the cover (1).

7. Check the level of the hydraulic fluid and add more if necessary. See “Filling the reservoir”.

NOTE: Install a new inlet filter when the hydraulic oil is replaced.

5-44

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Chapter 6 MAINTENANCE AND ADJUSTMENTS TABLE OF CONTENTS TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Track Shoe Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator And Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fan And Alternator Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Tank Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspecting And Cleaning The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5 6-5 6-6 6-7 6-7

REPLACING A BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 CAB SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Air Conditioning (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 HARDWARE TORQUE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 TORQUE CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6-1

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

NOTES

6-2

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

TRACKS IMPORTANT: If tracks are too tight, they wear quickly. If tracks are not tight enough, they wear quickly and the links can catch on the sprocket wheel or slide off the idler wheel or the sprocket wheel. Clean the tracks after working.

Cleaning

Checking Track Tension

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

1. Park the machine on firm, level ground. Keep all non-authorized personnel clear of the area.

2. Clean the tracks.

. .

CS01D529

Figure 1 CS01D529

1. Keep all non-authorized personnel clear of the machine. Move the machine to firm, level ground.

2. Position the upper structure at right angles to the undercarriage. Use the attachment to press on the ground, and lower the boom until the track is raised off the ground.

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

3. Use the travel speed selector to select high speed.

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

Figure 2

3. Place the upper structure at right angles to the undercarriage. Use the attachment to press on the ground, and lower the boom until the track is raised off the ground.

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

5. Repeat Steps 1 to 4 for the other track.

PEO7531

Figure 3

6. Measure the sag of the track at the center between the base of the undercarriage and the pad. The value should be 10.2 to 11.0 in (260 to 280 mm).

7. Adjust tension if necessary and then lower the raised track to the ground.

8. Repeat Steps 3 to 7 for the other track.

6-3

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS To Reduce Tension

Adjusting Tension Make any necessary track adjustments after the track tension has been checked.

.

To Increase Tension .

Figure 6

CT06M033

WARNING CT06M032

Figure 4

Pressurized fluid can penetrate the skin and cause severe injuries. The grease in the cylinder is under high pressure. Never loosen the grease fitting adaptor completely in order to speed up the flow of grease. Failure to comply could result in death or serious injury.

1. With the track in raised position, clean the grease fitting adaptor, and connect the grease pump hose to the grease fitting. .

WO261A

1. With the track in raised position, loosen the grease fitting adaptor about three turns to allow grease to flow out of the cylinder. .

PE07531

Figure 5

2. Connect the grease pump. Inject grease to obtain the right amount of track tension. The value should be 10.2 to 11.0 in (260 to 280 mm).

Remove the grease pump, clean the grease fitting, and then lower the raised track to the ground.

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

PE07531

Figure 7

2. When the correct track tension is obtained, tighten the adaptor. The value should be 10.2 to 11.0 in (260 to 280 mm).

3. Clean the grease adaptor and fitting.

4. Lower the raised track, and repeat Steps 1 to 3 for the other track.

5. If the grease fitting adaptor is damaged, grease may leak out. Check the condition of the grease fitting adaptor regular ly, and replace it, if necessary.

6-4

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TRACK SHOE BOLT TORQUE

GENERAL MAINTENANCE

Check track shoe bolt torque every 250 hours of machine operation.

RADIATOR AND OIL COOLER Clean the radiator and oil cooler area every 500 hours. Check daily for any leakage.

1

3

4

2

CS00E504

Figure 8

Tighten in the order shown.

Figure 10

CT07A064

1. Keep all non-essential personnel clear of the area. Stop the engine and remove the starter switch key.

2. Open the left hand side door and secure with the suppor ting strut. Open the engine hood, supporting properly.

PE08316

1

Figure 9

Tighten the track shoe bolts to a torque of: 804 Nm + 120° (592 ft lbs).

2

Figure 11

CT07A097

3. Remove wing nuts (1) and protective grilles (2).

4. Clean the radiator and oil coolers using compressed air or water.

5. Reinstall the protective grill and wing nuts.

WARNING Flying debris! Always wear protective clothing and safety glasses or a face shield when using a steam cleaner or power washer. Failure to comply could result in death or serious injury.

W314A

6-5

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS FAN AND ALTERNATOR DRIVE BELT

Tension Adjustment

Check the fan and alternator drive belt tension when the hour meter registers 500 hours. Adjust or the replace the belt if necessary.

2

Visually check the fan and alternator drive belt daily.

Tension Check

1

Figure 14

CT07A098

To adjust tension, loosen the mounting bolts (1). Use the adjustment screws (2) to move the alternator outwards until belt tension is correct. Retighten the pulley attachment to a torque of 147 Nm (108 ft lbs).

Tighten the alternator mounting bolt.

CT07A098

Figure 12

Replacing Drive Belt

2

CS98M560

1

Figure 13

With the engine off, and the star ter switch key removed, press the center of the belt, exerting a pressure of about 10 kg (20 lbs). The belt deflection should be about 6 to 8 mm (.2 to .3 in).

Check if there are any signs of wear damage to the pulleys or the belt. Check carefully to ensure that the belt is correctly positioned in the pulley grooves. If the belt is stretched, cracked or frayed, it must be replaced.

CT07A098

Figure 15

1. Remove the mounting bolts (1). Use the adjustment screws (2) to push the alternator inwards.

2. Remove the worn belt.

3. Install a new belt. Adjust the belt using the screw (2).

4. Tighten the mounting bolts (1) and retaining screw (2).

5. Run the engine for about an hour, and then check the belt tension again.

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.

6-6

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS FUEL TANK FILTER

INSPECTING AND CLEANING THE MACHINE

The fuel tank screen should be cleaned periodically.

Inspect and clean the machine periodically or whenever oil or grease has been spilled on the machine. Clean off with steam or a high pressure water jet. Use personal protection equipment when cleaning the machine.

Take the opportunity during this operation to make a visual check of all the welded components (in case of appearance of cracks), the attachment linkages and check the teeth and tooth tips for correct retention and for wear. Look for any leaks and check the condition of all pipes and hoses.

WELDING ON THE MACHINE Figure 16

CT07A099

Remove the screen and clean it in diesel fuel.

NOTE: To refill the fuel tank, see “Fluids and lubricants” in the “Lubrication/Filters/Fluids” Section.

WARNING Fire hazard! When handling diesel fuel, observe the following precautions: 1. Do not smoke. 2. Never fill the tank when the engine is running. 3. Wipe up spilled fuel immediately.Failure to comply could result in death or serious injury.

W0019A

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

IMPORTANT: Before you use an electric welder, disconnect the alternator wires, instrument cluster, and turn the master disconnect switch to OFF.

WARNING Improper operation or service of this machine can result in an accident. Any unauthorized modifications made to this machine can have serious consequences. Consult an authorized dealer on changes, additions, or modifications that may be required for this machine. Do not make any unauthorized modifications. Failure to comply could result in death or serious injury.

W0019A

6-7

CHAPTER 6 - MAINTENANCE AND 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.

3. Extend the cylinder rod.

4. Carry out the leak test by applying a piece of paper to the rod.

1. Wipe the cylinder rod and bearing off.

2. Operate normally for five or ten minutes.

Rod appearance Dry Slightly oily Oily

Test Slight traces of oil when a piece of paper is wiped over 20 cm of the rod.

Normal

Paper remains stuck to rod when run over rod.

Normal

Paper remains stuck when placed on rod.

Normal

Very oily or weeping

Each time cylinder rod is extended, a ring of oil can be seen on the rod.

Leakage

Each time the rod retracts, the excess oil drips from the gland.

PLASTIC AND RESIN PARTS When cleaning plastic parts such as the instrument console or the control arms, do not use gasoline, kerosene, paint solvents, etc. Use soap and water and a clean cloth only.

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

6-8

Conclusion

Consult your CASE Dealer

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

REPLACING A BUCKET REMOVAL 1. Keep all non-authorized personnel clear of the area. Position the bucket flat on firm, level ground. Operate the attachment controls so that the arm/bucket linkage pin is not held in place by the weight of the arm.

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

CD0E099

Figure 19

5. Start the engine, disengage the attachment from the bucket and retain the linkage seals for reuse.

CD00E096

Figure 17

3. Remove the retaining rings and pins.

CD00E097

Figure 18

4. Remove the bucket pins.

6-9

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS INSTALLATION 1. Make sure the bucket is in a stable position.

Figure 22

CD00E096

CD00E099

Figure 20

2. Install the linkage seals on the arm bushing shoulders. Change them if necessary.

3. Keep all non-authorized personnel clear of the area. Star t the engine. Extend the bucket cylinder rod to bring it into its housing. Stop the engine, and remove the starter switch key.

6. Install the connecting arm/bucket linkage pin, and then install the retaining pin and ring.

7. Push the seals back into their housing.

8. Adjust the arm/bucket shimming.

9. Grease the linkages.

WARNING Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. Failure to comply could result in death or serious injury.

C0044A

CD00E100

Figure 21

4. Install the arm/bucket linkage pin and then install the retaining pin and ring.

5. Start the engine, and bring the bucket connecting rod into its housing. Stop the engine, and remove the starter switch key.

6-10

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Replacing a tooth on the bucket

Shimming the Bucket

1

J 2 CD00E121

Figure 23

Side play adjustment 1. Place the bucket firm on level, firm ground.

2. Check the play (J) between the arm and the bucket ear.

3. If the play (J) exceeds 2 mm (.07 in), remove the four screws, the cap (1) and the shims (2).

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

5. Install the necessary number of shims.

6. Install the cap (1) and the four screws.

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

IMPORTANT: The inner bushing has a lug which prevents it from turning. The cap (1) has an orifice on its inside surface. When installing the cap (1), make certain the lug is inside this orifice.

CD01D128

Figure 24

REMOVAL 1. Keep all non-authorized personnel clear of the area. Position the bucket a few inches above the ground. Stop the engine and remove the starter switch key.

2. Use a drift to remove the locking pin from its housing by striking it with a hammer until it is ejected.

3. Remove the worn tooth tip, turning it to the left.

INSTALLATION 1. Clean the mating surface on the adaptor.

2. Install a new tooth tip up to the stop, turning it to the right and holding it in this position.

3. Place the locking pin in position, and strike it until it is flush with the tooth tip.

IMPORTANT: Make sure that the latch has been installed with the correct orientation.

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

TEETH AND TOOTH TIP WEAR LIMITS The degree to which teeth or tooth tips are worn can be assessed visually.

It is possible to extend the life of teeth or tooth tips which are wearing unevenly in a non-symmetrical fashion by interchanging them regularly.

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 could be seriously damaged.

6-11

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

CAB SERVICE AIR CONDITIONING (IF EQUIPPED) The components of the operator’s cab, including the components of the air conditioning system, require service at different intervals. Service the following items as required to maintain maximum operating efficiency.

WARNING Liquid refrigerant can cause severe and painful frostbite to your skin. Do not attempt to service the air conditioning system on this machine unless you are completely familiarized with air conditioning and the safety precautions which must be followed. Failure to comply could result in death or serious injury.

SA045

Lubrication Of The Air Conditioning Compressor Seals Operate the air conditioning once every 250 hours to lub r icat e th e co m pr ess or s ea ls. Tu r n th e a ir conditioning control to MAXIMUM for at least 15 minutes. In temperatures below 32°F (0°C) put a cover over the air conditioning condenser. This will allow the refrigerant and lubricants in the system to be at operating temperature.

Keep the air conditioning condenser core clean. Use compressed air (wear face protection) or a rigid brush to clean the condenser. Also check and clean the grille screen.

IMPORTANT: Because the condenser fins bend easily, use care when cleaning the condenser.

6-12

Inspection In order to ensure the air conditioning functions correctly, inspect the air conditioner using the procedure outlined below prior to starting work.

Cleanliness of the Condenser If the condenser is dirty, it will not dissipate heat properly. Clean the condenser in water.

IMPORTANT: Never use water under pressure to clean the condenser.

Check the Air Conditioning Lines Make a visual check of lines and make certain there is no accumulation of dust, grease, etc.

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS Checking The Air Conditioning Circuit Charge Level

CT02D235

Figure 25

CT07A102

1. Turn on the air conditioning system, increase engine speed slightly (1400 to 1600 rpm) and look for bubbles through the sight glass.

A

B

3. Check the air conditioning connectors to make certain they are not dusty or dirty.

AIR CONDITIONING DRIVE BELT

C

CT07A100 CS00E555

Figure 27

Figure 26

2. This check should be made approximately one minute after turning on the air conditioning.

A. Few bubbles observed. Transparent at first, then whitish. “Normal”.

Figure 28

With engine off, exert pressure of approximately 10 kg (22 lb force) on the center of the air conditioning drive belt. The amount of deflection should be between 6 to 8 mm (.2 to .3 in). Adjust the tension of the belt if necessary.

B. Many bubbles. Check all connections and see your CASE Dealer.

C. No bubbles visible. Check all connections and see your CASE Dealer.

6-13

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS CLEANING THE AIR RECYCLING FILTER

CLEANING THE AIR INTAKE FILTER

2

1

Figure 29 Figure 32

CT06K036

1. Clean the air intake filter every 50 hours.

Remove the screws (2) and sealing cover (1) in the battery compartment.

1. The air recycling filter should be cleaned every 50 hours. The filter is located behind the operator’s seat. Remove the access panel and take out the filter (1).

1

3

4

Figure 30

CT06K111

2. Remove the screws (3) and open the panel (4).

CT06K113

Figure 33

IMPORTANT: Use a safety type air gun and always protect your face before using compressed air.

2. Clean the filter (1) with compressed air. Replace the filter if it is damaged.

5

3. Install the filter and the access panel.

CT06K112

Figure 31

IMPORTANT: Use a safety type air gun and always protect your face before using compressed air.

3. Remove the filter, and clean it with compressed air. Replace the filter if it is damaged.

4. Install the filter in its housing with the seal (5) on the inside.

5. Close the panel (4) and install the screws (3).

6. Install the sealing cover (1) and the screws.

6-14

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

HARDWARE TORQUE INSPECTION At the end of each working day, check all mounting nuts and screws for tightness and tighten, if necessary. Make sure no hardware items are missing. Replace them, if necessary.

TORQUE SPECIFICATIONS PER COMPONENT

Component

Bolt Size

Torque (Ft.Lbs)

Torque (Nm)

Travel reduction gear (*)

M16

197-230

267-312

Drive sprocket (*)

M16

197-2302

267-312

Idler wheel (*)

M16

197-230

267-312

Upper roller (*)

M20

384-448

521-608

Lower roller (*)

M18

274-319

371-432

Chain guide (*)

M18

295-341

400-462

Track shoe

M20

221°

300 + 120°

Counterweight

M33

1373-1518

1862-2058

Turntable undercarriage

M20

345-402

468-5454

Turntable upper structure

M20/M24

345-402/578-674

468-545/784-914

Swing reduction gear (*)

M20/M24

398-465/578-674

539-630/784-914

Engine Bracket

M12

47-55

64-74

Engine mounts (*)

M16

47-55

64-74

Radiator

M12

108-131

147-177

Hydraulic pump (*)

M10 M16

47-54 164-182

64-73 223-247

Hydraulic reservoir (*)

M16

171-204

232-276

Fuel tank (*)

M16

171-204

232-276

Control valve (*)

M16

243-266

330-360

Hydraulic swivel(*)

M12 M16

65-79 80-94

88-107 109-127

Cab

M16

180-217

245-294

Battery

M10

15-21

20-29

NOTE: Use Loctite 262, or the equivalent, on bolts marked (*).

6-15

CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

TORQUE CHARTS Use these charts when special torques are not given. These torques apply to fasteners with both UNC and UNF threads as received from suppliers dry, or when lubricated with engine oil. Not applicable if special graphite, Molydisulfide greases, or other extreme pressure lubricants are used.

Grade 8 Bolts, Nuts, and Studs

Grade 5 Bolts, Nuts, and Studs

PoundInches

Newton metres

1/4 inch

108 to 132

12 to 15

5/16 inch

204 to 252

23 to 28

3/8 inch

420 to 504

48 to 57

7/16 inch

54 to 64

73 to 87

1/2 inch

80 to 96

109 to 130

9/16 inch

110 to 132

149 to 179

5/8 inch

150 to 180

203 to 244

3/4 inch

270 to 324

366 to 439

7/8 inch

400 to 480

542 to 651

1.0 inch

580 to 696

787 to 944

1-1/8 inch

800 to 880

1085 to 1193

1-1/4 inch

1120 to 1240

1519 to 1681

1-3/8 inch

1460 to 1680

1980 to 2278

1-1/2 inch

1940 to 2200

2631 to 2983

Size

PoundInches

Newton metres

1/4 inch

144 to 180

16 to 20

5/16 inch

288 to 348

33 to 39

3/8 inch

540 to 648

61 to 73

7/16 inch

70 to 84

95 to 114

1/2 inch

110 to 132

149 to 179

9/16 inch

160 to 192

217 to 260

5/8 inch

220 to 264

298 to 358

3/4 inch

380 to 456

515 to 618

7/8 inch

600 to 720

814 to 976

1.0 inch

900 to 1080

1220 to 1465

1-1/8 inch

1280 to 1440

1736 to 1953

1-1/4 inch

1820 to 2000

2468 to 2712

1-3/8 inch

2380 to 2720

3227 to 3688

1-1/2 inch

3160 to 3560

4285 to 4827

Size

NOTE: Use thick nuts with Grade 8 bolts.

6-16

CHAPTER 7 - ELECTRICAL

Chapter 7 ELECTRICAL TABLE OF CONTENTS ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning the Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the Battery Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing a Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Booster Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3 7-3 7-4 7-4 7-4 7-4 7-5 7-5 7-5

FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Replacing a Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7-1

CHAPTER 7 - ELECTRICAL

NOTES

7-2

CHAPTER 7 - ELECTRICAL

ELECTRICAL SYSTEM BATTERY SAFETY

WARNING WARNING Hazardous chemicals! Battery electrolyte contains sulfuric acid. Contact with skin and eyes could result i n s eve r e i r r it a t i o n a n d bu r n s. A l way s we a r splash-proof goggles and protective clothing (gloves and aprons). Wash hands after handling. Failure to comply could result in death or serious injury.

WO006A

WARNING

Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote - EXTERNAL: flush with water.

NTERNAL: drink large quantities of water or milk.

Follow with milk of magnesia, beaten egg or vegetable oil. Call physician immediately.

EYES: flush with water for 15 minutes and get prompt medical attention. Failure to comply could result in serious injury or death.

SB032A

Explosive gas! Batteries emit explosive hydrogen gas and other fumes while charging. Ventilate the charging area. Keep the battery away from sparks, open flames, and other ignition sources. Never charge a frozen battery. Failure to comply could result in serious injury or death.

WO005A

WARNING To prevent an explosion: 1. Always disconnect the negative (-) battery cable first. 2. Always connect the negative (-) battery cable last. 3. Do not short circuit the battery posts with metal objects. 4. Do not weld, grind, or smoke near a battery. Failure to comply could result in serious injury or death.

WO005A

WARNING

WARNING When the battery electrolyte is frozen, the battery can explode if, (1) you try to charge the battery, or (2) you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured. Failure to comply could result in serious injury or death.

SA033A

WARNING Electrical shock hazard! Do not reverse battery terminals. Connect positive cable ends to positive terminals (+) and negative cable ends to negative terminals (-). Failure to comply could result in serious injury or death.

W0162A

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

Antidote (external): Flush with water. Antidote (eyes): flush with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large quantities of water or milk. Do not induce vomiting. Seek medical attention immediately.

Failure to comply could result in serious injury or death.

WO111A

WARNING Electrical shock hazard! Before working on any part of the electrical system, disconnect the battery ground cable. Complete all electrical work before connecting the cable. Failure to comply could result in serious injury or death.

W0129A

7-3

CHAPTER 7 - ELECTRICAL BATTERY SERVICE Before you service components of the electrical system, always disconnect the NEGATIVE (-) battery cable.

Dirt, moisture, and corrosion on the battery will discharge the battery. Clean the battery with Case Battery Saver and Cleaner. Follow the instructions on the container.

Disconnect the alternator wires if you must run the engine with the battery wires disconnected.

Before you use an electric welder, disconnect the alternator wires, instrument cluster, and turn the master disconnect switch to OFF. Do not use a steam cleaner or cleaning solvent to clean the alternator.

BATTERY FLUID LEVEL Check the fluid level of the batteries every 500 hours of operation. If the fluid level is low, add distilled water to each cell until the fluid level is at the split ring at the bottom of each cell opening.

In extreme heat conditions check battery fluid every 250 hours.

ACCESSING BATTERIES

CT06K074

Figure 1

To access the batteries, open the left hand side door, and remove the skid plate.

7-4

IMPORTANT: If the temperature is 0°C (32°F) or below and you have added water to the batteries, you must: Connect a battery charger to the batteries or operate the machine for approximately two hours.

This procedure is necessary to mix the water with the electrolyte.

BATTERY VENTS Keep the battery vents clean, make sure the vents are not restricted.

CLEANING THE BATTERIES Check the batteries and batter y compar tment regularly for dirt, corrosion and damage. Dirt mixed with electrolyte or moisture on the top of the batteries can cause a discharged condition in the batteries.

Use one of the following methods to clean the batteries.

• Use Case Battery Saver, Part Number M20376.

Follow the instructions on the container. This cleaner does not need water.

Use baking soda or ammonia and flush the outside of the batteries with water. If you do not have Case Battery Saver, use other special cleaners to prevent corrosion on the battery terminals.

CHAPTER 7 - ELECTRICAL CHECKING THE BATTERY ELECTROLYTE LEVEL

REPLACING A BATTERY

CD0E094 CD01D132

Figure 2

To gain access to the batteries, open the left-hand side door and remove the skid plate.

Remove the cell caps and check the level in each cell of both batteries. The level should be between 10 and 15 mm (.3 to .5 in) above the plates. Add distilled water if necessary, then install the cell caps.

IMPORTANT: When adding distilled water at temperatures below 0° C (32° F), the batteries must be charged or the engine run for two hours approximately in order to 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.

Figure 3

Remove the terminal protection caps, disconnect cables at negative terminals and then disconnect cables at positive terminals. Remove the anti-sulfate pellets.

Remove the two screws, the washers and metal sheet. Remove the old battery.

Install the new battery and put the metal sheet, washers and screws back in place.

Clean the cables and battery terminals, and coat them with grease.

Install new anti-sulfate pellets, reconnect positive cable ends to positive ter minals first and then negative cable ends to negative terminals. Install the terminal protection caps.

7-5

CHAPTER 7 - ELECTRICAL CONNECTING BOOSTER BATTERIES

WARNING Electrical shock hazard! Do not reverse battery terminals. Connect positive cable ends to positive terminals (+) and negative cable ends to negative terminals (-). Failure to comply could result in serious injury or death.

W0262A

WARNING When jump-starting the machine, connect and disconnect the jumper cables exactly as indicated in this manual.

DO NOT connect the jumper cables to the machine battery terminals. Make sure no persons are near the connecting points before starting the engine. Start the engine from the operator’s seat. Failure to comply could result in serious injury or death.

W0342A

Make sure that the voltage of the booster batteries is the same as that of the machine system.

1. Turn off the ignition and all accessories on the machine(s). Remove the battery terminal covers.

4. Connect the other end of the negative cable to the engine block or frame of the machine with the discharged battery. Do not connect it to sheet metal or any rotating part, as damage can result.

2. Connect one end of the positive (+) cable to the positive (+) terminal on the booster battery.

Connect the other end of the positive (+) cable to the positive (+) ter minal of the discharged battery.

5. Start the engine.

3. Connect the negative (-) cable to the negative (-) terminal on the booster battery.

7. Install the terminal covers.

7-6

6. Remove the booster battery negative (-) cable from the machine, then from the booster battery.

Remove the positive (+) cable from the machine and then from the booster battery.

CHAPTER 7 - ELECTRICAL

FUSES AND RELAYS IMPORTANT: Before replacing a fuse, turn the starter switch key to “OFF”.

IMPORTANT: Never replace a fuse with a fuse of a different amperage.

CT06K036

Figure 4

To gain access to the fuses, open the panel at the rear of the operator’s compartment, and remove the cover.

A23955

Figure 6

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.

NOTE: Two spare fuses (10 amp and 20 amp) can be found on the inside of the fuse box cover.

CT06K037

Figure 5

To access the fuses, remove the cover of the box.

7-7

CHAPTER 7 - ELECTRICAL FUSES (1) Memory, cab light, car radio . . . . . . . . . . . . . 10 A (2) Engine pre-heating . . . . . . . . . . . . . . . . . . . . 30 A (3) Optional. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 A (4) Air conditioning, heater . . . . . . . . . . . . . . . . . . 5 A (5) Air conditioning condenser fan . . . . . . . . . . . 15 A (6) Air conditioning compressor . . . . . . . . . . . . . . 5 A (7) Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 A (8) Windshield wiper/washer . . . . . . . . . . . . . . . 15 A (9) Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 A (10) Cab light . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 A (11) Fuel filler pump (if equipped). . . . . . . . . . . . 20 A (12) Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 A (13) Cigarette lighter, operator’s seat . . . . . . . . . 15 A (14) DC rectifier . . . . . . . . . . . . . . . . . . . . . . . . . 10 A (15) Rotating beacon (not supplied) . . . . . . . . . . 10 A (16) Not used . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 A (17) Fuel supply pump . . . . . . . . . . . . . . . . . . . . 10 A (18) Not used . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 A (19) Hydraulic control cancellation . . . . . . . . . . . 10 A (20) Work lights . . . . . . . . . . . . . . . . . . . . . . . . . 15 A

KHP12180

1

10A

20A

11

2

30A

10A

12

10A

15A

4

5A

10A

14

5

15A

10A

15

6

5A

15A

16

10A

10A

15A

15A

10A

10A

15A

15A

3

7 8 9 10

13

17 18 19 20

CT06K073

8

7-8

CHAPTER 7 - ELECTRICAL REPLACING A BULB Cab Light

CD00E126

Figure 10

Figure 7

3. Pull the clip outwards, remove the bulb, and install a bulb of the same wattage (70 W).

2. Remove the bulb, and install a bulb of the same wattage (10 W).

IMPORTANT: Never put your fingers on a tungsten iodide bulb.

CD00E123

1. Remove the lens by hand.

3. Install the lens.

4. Install the clip and reconnect the plug.

5. Put the work light back into position, and install the mounting screws.

Work Light

CD00E124

Figure 8

1. Remove the four mounting screws.

CD00E125

Figure 9

2. Tilt the work light and disconnect the plug.

7-9

CHAPTER 7 - ELECTRICAL Upper Structure Work Light

CD00E129 CT06K057

Figure 11

1. Open the front storage box.

CT06K069

Figure 12

2. Remove the switch bracket to access the head lamp.

Figure 14

4. Remove four screws and tilt the work light (upper structure work light).

CD00E130

Figure 15

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 and the work light assembly.

7. Install the work light and plug (upper structure work light)

CD00E128

3. Disconnect the plug.

7-10

Figure 13

CHAPTER 8 - SPECIFICATIONS

Chapter 8 SPECIFICATIONS TABLE OF CONTENTS ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 OPERATOR’S COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 MONOBLOC BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 SWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 LIFTING CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 BUCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 Digging Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

8-1

CHAPTER 8 - SPECIFICATIONS

NOTES

8-2

CHAPTER 8 - SPECIFICATIONS

ENGINE SPECIFICATIONS NOTE: All specifications are given according to SAE Standards or Recommended Practices where the specification applies.

Model............................................................................................................................................................ AI-4JJ1X Manufacturer....................................................................................................................................................... Isuzu Turbocharged......................................................................................................................................................... yes Number of cylinders...................................................................................................................................................4 Bore/stroke .............................................................................................................. 3.76 x 4.13 in (95.4 x 104.9 mm) Displacement................................................................................................................................ 183 cu in (2999 cc) SAE net horsepower - rated ........................................................................................ 120hp (89.2 kW) @ 2200 rpm Injection .............................................................................................................................................................. direct Injection pump ............................................................................................................................................. electronic Battery start ................................................................................................................... 2 12/24 volt batteries, 72 A/h Cooling .............................................................................................................................................................. water Charge air cooling ................................................................................................................................................. Yes Starter....................................................................................................................................................24 V (4.0 kW) Alternator ........................................................................................................................................................ 50 Amp Starting Aid ................................................................................................................................................. Glow Plug Oil capacity (crank case and filter) .........................................................................................................4.5 gal (17 L)

8-3

CHAPTER 8 - SPECIFICATIONS

HYDRAULIC SYSTEM Main pumps Variable displacement - axial piston with regulating system Quantity ..................................................................................................................................................................... 2 Flow each .................................................................................................................................. 37.5 gpm (142 L/mn) Pilot pump Fixed displacement - gear type Quantity ..................................................................................................................................................................... 1 Flow ................................................................................................................................................. 5.9 gpm (22 L/m) Circuit pressure ...........................................................................................................................570 psi (40 kgf/cm2) Tilting oil cooler with ventilation from engine.

High pressure multispiral hoses Self-lubricating hydraulic swivel.

Hydraulic reservoir capacity ....................................................................................................................24 gal (90 L) Total hydraulic system capacity .............................................................................................................44 gal (165 L)

CONTROL VALVE Four control valve sections for right track travel, boom, bucket and arm acceleration.

Five control valve sections for left track travel, swing, arm, auxiliary attachment and boom acceleration.

SWING Motor ......................................................................................................................... Fixed displacement axial piston Gear box.......................................................................................................................................................Planetary Brake ...................................................................................................................................... Mechanical disk brake.

Turntable bearing................................................................................................................ ball bearing, internal gear Upper structure swing speed (maximum) ......................................................................................................11.5 rpm

TRAVEL Two speed hydraulic motors with axial pistons.

Planetary reduction gears Low speed .......................................................................................................................0 to 2.0 mph (0 to 2.8 km/h) High speed ......................................................................................................................0 to 3.4 mph (0 to 5.4 km/h) Gradeability ..........................................................................................................................................................70%

WEIGHTS STANDARD MACHINE With 2.62 m (8 ft 7 in) arm, bucket, 23.6 in (900 mm) shoes, 165 lb (75 kg) operator and full fuel tank .................................................................................. 37700 lbs (17100 kg).

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, waterproof outside electrical connectors Safety glass, horn, travel alarm Inertia reel type safety belt Safety valves with overload indicator.............................................................................................................. optional Fire extinguisher ............................................................................................................................................. optional

8-4

CHAPTER 8 - SPECIFICATIONS

OPERATOR’S COMPARTMENT High comfort seat with armrests, inertia reel type safety belt, multiple adjustments and head rest.

Hydraulically assisted controls.

Attachment and swing .........................................................................................................................2 control levers Travel ...................................................................................................................................................... 2 foot pedals Single-speed wiper plus intermittent mode, washers, heating, defrost, ventilation/air conditioning, cab lighting, sky-light, cigarette lighter, sun shield.

Work lights: On upper structure (1)........................................................................................................................... 24 V, 70 W On attachment (2) ................................................................................................................................. 24 V, 70 W On cab (2) ............................................................................................................................................. 24 V, 70 W

CAB • • • •

• • • •

Safety glass Sliding front window Rear window emergency exit.

AM/FM radio Climate control Hinged skylight

LCD monitor display Anti-theft device Windshield protection grille...........................................................................................................................(optional) Cab guard.....................................................................................................................................................(optional)

MONOBLOC BOOM Length............................................................................................................................................16 ft 11 in (5.15 m) Free swing control, hammer adaptable, swing brake

ARMS 2.23 m (7 ft 4 in)

3.04 m (10 ft 0 in)

2.62 m (8 ft 7 in)

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

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

SWING Motor ......................................................................................................................... Fixed displacement axial piston Gear box .......................................................................................................................................................Planetary Brake .........................................................................................................................................Automatic disk brake.

Turntable bearing............................................................................................... single row ball bearing, internal gear Upper structure swing speed (maximum) ...........................................................................................................9 rpm

8-5

CHAPTER 8 - SPECIFICATIONS

DIMENSIONS

BS06K186

8-6

Figure 1

CHAPTER 8 - SPECIFICATIONS 2.23 M (7 ft 4 in) ARM (A) Overall height.............................................................................................................................9 ft 10 in (3.00 m) (B) Cab Height...................................................................................................................................9 ft 7 in (2.93 m) (C) Overall length...........................................................................................................................27 ft 10 in (8.49 m) (D) Overall length without attachment .............................................................................................13 ft 6 in (4.11 m) (E) Width of upper structure without catwalk .....................................................................................8 ft 4 in (2.54 m) (F) Width of upper structure with catwalk ........................................................................................12 ft 0 in (3.65 m) (G) Track overall length....................................................................................................................13 ft 1 in (3.99 m) (H) Track overall width .......................................................................................................................8 ft 6 in (2.59 m) (I) Track shoe width...........................................................................................................................23.6 in (600 mm) (J) Center to center (idler to sprocket) .............................................................................................10 ft 6 in (3.19 m) (K) Upper structure ground clearance ...............................................................................................3 ft 4 in (1.02 m) (L) Minimum ground clearance ..........................................................................................................1 ft 5 in (0.44 m) (M) Tail swing radius ..........................................................................................................................8 ft 0 in (2.45 m) 2.62 M (8 ft 7 in) ARM (A) Overall height...............................................................................................................................9 ft 9 in (2.96 m) (B) Cab Height...................................................................................................................................9 ft 7 in (2.93 m) (C) Overall length.............................................................................................................................27 ft 8 in (8.44 m) (D) Overall length without attachment .............................................................................................13 ft 6 in (4.11 m) (E) Width of upper structure without catwalk .....................................................................................8 ft 4 in (2.54 m) (F) Width of upper structure with catwalk ........................................................................................12 ft 0 in (3.65 m) (G) Track overall length....................................................................................................................13 ft 1 in (3.99 m) (H) Track overall width .......................................................................................................................8 ft 6 in (2.59 m) (I) Track shoe width...........................................................................................................................23.7 in (600 mm) (J) Center to center (idler to sprocket) .............................................................................................10 ft 6 in (3.19 m) (K) Upper structure ground clearance ...............................................................................................3 ft 4 in (1.02 m) (L) Minimum ground clearance ..........................................................................................................1 ft 5 in (0.44 m) (M) Tail swing radius ..........................................................................................................................8 ft 0 in (2.45 m) ((O) Track gauge................................................................................................................................6 ft 6 in (1.99 m)

3.04 M (10 ft 0 in) ARM (A) Overall height.............................................................................................................................10 ft 3 in (3.13 m) (B) Cab Height...................................................................................................................................9 ft 7 in (2.93 m) (C) Overall length............................................................................................................................27 ft 11in (8.52 m) (D) Overall length without attachment .............................................................................................13 ft 6 in (4.11 m) (E) Width of upper structure without catwalk .....................................................................................8 ft 4 in (2.54 m) (F) Width of upper structure with catwalk ........................................................................................12 ft 0 in (3.65 m) (G) Track overall length....................................................................................................................13 ft 1 in (3.99 m) (H) Track overall width .......................................................................................................................8 ft 6 in (2.59 m) (I) Track shoe width...........................................................................................................................23.7 in (600 mm) (J) Center to center (idler to sprocket) .............................................................................................10 ft 6 in (3.19 m) (K) Upper structure ground clearance ...............................................................................................3 ft 4 in (1.02 m) (L) Minimum ground clearance ..........................................................................................................1 ft 5 in (0.44 m) (M) Tail swing radius ..........................................................................................................................8 ft 0 in (2.45 m) (O) Track gauge .................................................................................................................................6 ft 6 in (1.99 m)

8-7

CHAPTER 8 - SPECIFICATIONS WORKING RANGE

BS06K188

8-8

Figure 2

CHAPTER 8 - SPECIFICATIONS

2.23 M (7 FT 4 IN) (A) Maximum dig radius...................................................................................................................28 ft 5 in (8.67 m) (B) Dig radius at ground line ..........................................................................................................27 ft 11 in (8.50 m) (C) Maximum digging depth ............................................................................................................18 ft 7 in (5.66 m) (D) Dig depth - 8 ft.(2.44 m) level bottom ......................................................................................17 ft 10 in (5.43 m) (E) Maximum dump height ............................................................................................................20 ft 11 in (6.38 m) (F) Maximum working height ...........................................................................................................29 ft 7 in (9.01 m) (G) Minimum swing radius .................................................................................................................9 ft 9 in (2.98 m) (H) Vertical straight wall dig depth ...................................................................................................15 ft 6 in (4.72 m)

2.62 M (8 FT 7 IN) ARM (A) Maximum dig radius.................................................................................................................30 ft 10 in (9.40 m) (B) Dig radius at ground line ............................................................................................................29 ft 1 in (8.87 m) (C) Maximum digging depth ..........................................................................................................19 ft 11 in (6.06 m) (D) Dig depth - 8 ft.(2.44 m) level bottom ........................................................................................19 ft 2 in (5.85 m) (E) Maximum dump height ..............................................................................................................21 ft 8 in (6.61 m) (F) Maximum working height ...........................................................................................................30 ft 4 in (9.24 m) (G) Minimum swing radius ...............................................................................................................9 ft 10 in (2.99 m) (H) Vertical straight wall dig depth ...................................................................................................16 ft 8 in (5.08 m)

3.05 M (10 FT 0 IN) ARM (A) Maximum dig radius...................................................................................................................30 ft 9 in (9.38 m) (B) Dig radius at ground line ............................................................................................................30 ft 3 in (9.22 m) (C) Maximum digging depth ............................................................................................................21 ft 4 in (6.49 m) (D) Dig depth - 8 ft.(2.44 m) level bottom ........................................................................................20 ft 8 in (6.29 m) (E) Maximum dump height ............................................................................................................21 ft 11 in (6.69 m) (F) Maximum working height ...........................................................................................................30 ft 6 in (9.29 m) (G) Minimum swing radius .................................................................................................................9 ft 9 in (2.98 m) (H) Vertical straight wall dig depth ....................................................................................................17 ft 2in (5.22 m)

8-9

CHAPTER 8 - SPECIFICATIONS

LIFTING CAPABILITIES

5 1 4 3

2 B9408252

B9408252

1.

2.

3.

4.

5.

Figure 3

LOAD (LIFT) POINT HEIGHT LOAD (LIFT) POINT RADIUS SWING PIVOT GROUND LINE LOAD (LIFT) POINT ON BUCKET

• The lift point is the lifting eye on the back of the bucket.

• The mass of slings and any auxiliary lifting devices shall be deducted from the rated load to determine the net load that may be lifted.

• All rated lift capacities are based on the machine being level and on a firm supporting surface. For safe working loads, the user is expected to make due allowance for the particular job conditions such as soft or uneven ground, non-level conditions, side loads, hazardous conditions, experience of personnel, etc. The operator and other personnel should fully acquaint themselves with the operator’s manual furnished by the manufacturer before operating this machine, and rules for safe operation of equipment shall be adhered to at all times.

• Lifting capacities shown do not exceed 75% of minimum tipping loads or 87% of hydraulic capacities. Capacities marked with an asterisk (*) are limited by hydraulic capacities.

• Least stable position is over the side.

8-10

CHAPTER 8 - SPECIFICATIONS

BUCKETS General Purpose Plate Lip CU YD

1.76

2.14

2.52

2.91

3.29

4.05

Width (in)

36

42

48

54

60

66

Weight (lbs)

2764

3057

3252

3566

3752

4449

Heavy Duty Plate Lip CU YD

1.73

2.10

2.48

2.85

3.24

Width (in)

36

42

48

54

60

Weight (lbs)

3297

3621

3876

4221

4443

Extreme Duty Plate Lip CU YD

1.24

1.58

1.93

2.28

Width (in)

30

36

42

48

Weight (lbs)

3572

3880

4247

4527

Heavy Duty Cast Lip

CU YD

1.90

2.27

Width (in)

39

45

Weight (lbs)

3456

3808

8-11

CHAPTER 8 - SPECIFICATIONS

NOTES

8-12

CHAPTER 9 - INDEX

Chapter 9

INDEX A

F

Air Conditioning Compressor ................................................... 6-12 Condenser ..................................................... 6-12 Air filter ..................................................... 5-23, 5-30 Air recycling ....................................................... 3-21 Anti-theft device ................................................. 3-19 Anti-theft protection indicator ............................. 3-14 Attachment failure .............................................. 4-20

Fan and alternator drive belt ...................... 5-14, 6-6 Filter Engine ............................................................5-25 Fluid and Lubricants .............................................5-7 Fluids and lubricants ..........................................5-11 Footrest ..............................................................3-29 Front storage box ...............................................3-35 Fuel Handling Precautions ...................................2-9 Fuel level indicator .............................................3-14 Fuel tank .............................................................3-35 Fuel tank filling pump .........................................3-39 Function and message display screen ...............3-14

B Battery Cleaning .......................................................... 7-4 Fluid Level ....................................................... 7-4 Safety .............................................................. 7-3 Service ............................................................ 7-3 Vents ............................................................... 7-4 Before Operation Safety ...................................... 2-6 Bleeding ............................................................... 5-5 Bucket specifications ......................................... 8-11

C Cab light ............................................................ 3-31 Cab Service ....................................................... 6-12 Coat hanger hook .............................................. 3-31

G General Information ..............................................1-1 General Safety .....................................................5-3

H Hardware torque inspection ..................... 5-22, 6-15 Hazardous Chemical Precautions ......................2-10 Hourmeter, Engine ...............................................5-6 Hydraulic fluid .....................................................5-11 Hydraulic fluid temperature indicator ..................3-14 Hydraulic system .......................................... 8-4, 8-5

E Electrical System ................................................. 7-3 Engine Hourmeter ....................................................... 5-6 Specifications .................................................. 8-3 Engine coolant temperature indicator ................ 3-14 Engine Lubrication ............................................. 5-10 Engine Oil Selection ...................................... 5-10 Engine Oil Level ................................................ 5-13 Engine Oil Selection .......................................... 5-10 Engine Operation .......................................... 4-3, 4-5 Engine Speed .................................................. 4-5 Parking the Machine and Stopping the Engine 4-6 Starting the Engine .......................................... 4-5 Engine Service Engine Oil Level ............................................ 5-13 Oil Change and Filter Replacement .............. 5-25 Engine Speed ...................................................... 4-5 Engine starting procedure ................................... 4-7 Engine stopping procedure ................................ 4-10 Error code indicator ........................................... 3-14

I Identification Numbers Product Identification Number (P.I.N.) .............1-4 Inspecting and cleaning the machine ...................6-7 Instructions, General Safety .................................5-3 Instrument Panel ..................................................3-3

L Lifting loads ........................................................4-13 Load holding control device ................................3-38 Lower panels ......................................................3-36 Lowering the attachment in the event machine failure 4-20 Lubrication/Filters/Fluids Engine Lubrication .........................................5-10 Fluid and Lubricants .........................................5-7

M Machine Operation Safety ....................................2-6 Machine overall dimensions .................................8-6 Machine storage .................................................4-23 Machine travel ....................................................4-11 9-1

CHAPTER 9 - INDEX Maintenance Precautions .................................... 2-9 Maintenance, 10 Hour ..................... 5-13, 5-14, 5-16 Message display screen .................................... 3-15

O Oil Change Engine ........................................................... 5-25 Oil Viscosity/Temperature Ranges .................... 5-10 Operating in water ............................................. 4-17 Operating Instructions ......................................... 4-5 Operating Precautions ......................................... 2-7 Operating the backhoe bucket ........................... 4-18 Operating the machine in cold weather ............... 4-9 Operating the machine in hot weather ................. 4-9 Owner, To The ..................................................... 1-1

Starting the engine ...............................................4-7 Storage tray ........................................................3-33 Storing the machine ...........................................4-23 Sun shield ...........................................................3-33 Swing reduction gear ................................ 5-20, 5-35

T Temperature control system ...............................3-20 To the Owner ........................................................1-1 Towing the machine ...........................................4-20 Track Shoe Bolts ..................................................4-3 Transmission component oil ...............................5-11 Travel control levers and pedals ........................3-29

U Utility Safety Rules Message ................................2-4

P Parking the Machine and Stopping the Engine ... 4-6 Parking The Machine Safety ............................. 2-10 Personal Safety ................................................... 2-6 Plastic and Resin Parts ....................................... 5-6

Q Quick coupler locking/unlocking control ............ 3-31

R Radiators and oil coolers ................................... 5-24 Releasing Hydraulic System Pressure ................ 5-4 Replacing a tooth on the backhoe bucket ......... 6-11 Run-In Period of a New Machine Track Shoe Bolts ............................................. 4-3

S Safety Decals .................................................... 2-12 Safety Instructions, General ................................ 5-3 Safety, Battery ..................................................... 7-3 Safety, Decals, and Hand Signals Personal Safety ............................................... 2-6 Safety Rules .................................................... 2-3 Utility Safety .................................................... 2-4 Safety/Decals/Hand Signals Before Operation ............................................. 2-6 Machine Operation .......................................... 2-6 Parking The Machine .................................... 2-10 Safety Decals ................................................ 2-12 Sides of the machine Right-hand, left-hand, front, and rear .............. 1-3 Specifications Engine Specifications ...................................... 8-3 Start Up After Storage ....................................... 4-23 Starting and Stopping Precautions ...................... 2-7 Starting the Engine .............................................. 4-5 9-2

W Walk-Around Inspection .......................................4-5 Weights - Operating .............................................8-4 Working mode indicator ......................................3-14

Dealer’s stamp

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

Specifications, descriptions, and illustrative material herein are as accurate as known at time of publication, but are subject to change without notice.

Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your Case dealer.

Printed in U.S.A. Copyright © 2011 CNH America LLC. All Rights Reserved.

Case is a registered trademark of CNH America LLC. Racine Wisconsin 53404 U.S.A.