Case CX225SR Tier 3 Crawler Excavator Operator's Manual 84339042 - PDF DOWNLOAD

CX225SR Tier 3

Crawler excavator Operator's Manual Print No. Lep 84339042

CONSTRUCTION

3rd edition English 06/2010 - Original Instructions Replaces Lep 84213371 CONSTRUCTION

CX225SR Tier 3

Crawler excavator

Operator's Manual Print No. Lep 84339042

3rd edition English 06/2010 - Original Instructions Replaces Lep 84213371

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

• The lower panel indicates appropriate avoidance of the danger.

• Background colour is YELLOW. • Prohibition symbols such as

if used, are RED.

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

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

• Reads and understands ALL Safety Decals on the machine.

• Clears the area of other persons.

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

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

CNH France S.A. Company reserves the right to make changes in the specification and design of the machine without prior notice and without incurring any obligation to modify units previously sold.

The description of the models shown in this manual has been made in accordance with the technical specifications known as of the date of design of this document.

All data given in this manual is subject to production variations. Dimensions and weights are provided with approximate values and the machine fitting shown in the illustrations may not correspond with standard models. For precise information on specific machine models and versions, please consult your CASE Dealer.

Reproduction or translation, even partial, is prohibited without written authorization from CNH France S.A. Company Copyright © 2010 CNH France S.A.

Lep 84339042 EN Issued January 2008 (Revised June 2010)

OPERATOR’S MANUAL CX225SR Tier 3

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QUICK REFERENCE SECTION GUIDE Shown are the Sections contained within this book.

1 - To the owner 2 - Identification numbers/Machine components 3 - Safety/Decals/Hand signals 4 - Controls/Instruments/Accessories 5 - Operating instructions 6 - Servicing intervals 7 - Lubrication/Filters/Fluids 8 - Maintenance/Adjustments 9 - Electrical system 10 - Storage 11 - Specifications 12 - Alphabetical index

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TABLE OF CONTENTS SECTION 1 - TO THE OWNER .................................................................................................................. 1-1 Hydraulic crawler excavator CX225SR .................................................................................................... 1-1 Official documents .................................................................................................................................... 1-3 Right, left, front and rear of the machine .................................................................................................. 1-3 SECTION 2 - IDENTIFICATION NUMBERS/MACHINE COMPONENTS .................................................. 2-1 Type, serial number and year of manufacture of the machine ................................................................. 2-1 Description of the main components ........................................................................................................ 2-3 SECTION 3 - SAFETY/DECALS/HAND SIGNALS .................................................................................... 3-1 Safety instructions .................................................................................................................................... 3-1 Before using the machine ........................................................................................................................ 3-2 Operating the machine ............................................................................................................................. 3-3 Preventing risks caused by vibrations ...................................................................................................... 3-4 Cab protection (F.O.P.S.) ......................................................................................................................... 3-5 Quick coupler ........................................................................................................................................... 3-5 Safety area ............................................................................................................................................... 3-5 Using an implement other than a bucket .................................................................................................. 3-5 Implement operation and maintenance .................................................................................................... 3-5 Parking the machine ................................................................................................................................ 3-6 Maintenance and adjustments ................................................................................................................. 3-6 Preventing fires or explosions .................................................................................................................. 3-7 Prevention of burns .................................................................................................................................. 3-8 Decals ...................................................................................................................................................... 3-9 Hand signals .......................................................................................................................................... 3-22 SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES .................................................................... 4-1 Cab door .................................................................................................................................................. 4-1 Steps and access handles ....................................................................................................................... 4-2 Position of the operator’s compartment controls and accessories ........................................................... 4-3 Right-hand control arm ............................................................................................................................. 4-4 Instrument panel ...................................................................................................................................... 4-5 Left-hand control arm ............................................................................................................................... 4-7 Working light switch ................................................................................................................................. 4-9 Windshield washer switch ........................................................................................................................ 4-9 Windshield wiper switch ........................................................................................................................... 4-9 High speed travel switch ........................................................................................................................ 4-10 Heating and ventilation control ............................................................................................................... 4-11 Heating, ventilation or air-conditioning control ....................................................................................... 4-12 Quick coupler locking and unlocking control switch ............................................................................... 4-13 Control locking lever ............................................................................................................................... 4-13 Dipper and upperstructure swing LH control lever ................................................................................. 4-14 Boom and bucket RH control lever ........................................................................................................ 4-14 Travel control levers and pedals ............................................................................................................ 4-15 Option pedal ........................................................................................................................................... 4-15 Locking and unlocking the option pedal ................................................................................................. 4-16

TABLE OF CONTENTS Controls/Instruments/Accessories (continued) Dozer blade control lever ........................................................................................................................4-16 Cab light .................................................................................................................................................4-17 Coat hanger hook ...................................................................................................................................4-17 Rear RH side window .............................................................................................................................4-17 Glove compartment ................................................................................................................................4-18 Storage tray ............................................................................................................................................4-18 Ashtray ...................................................................................................................................................4-18 Sun shield ...............................................................................................................................................4-18 Cab radio compartment ..........................................................................................................................4-19 Speaker compartments ..........................................................................................................................4-19 Fuse box .................................................................................................................................................4-19 Operator's seat .......................................................................................................................................4-20 Windshield ..............................................................................................................................................4-24 Lower front window .................................................................................................................................4-26 Window-breaker hammer .......................................................................................................................4-27 Air vents ..................................................................................................................................................4-27 Rear view mirrors ...................................................................................................................................4-28 Fuel tank .................................................................................................................................................4-30 Upper hoods ...........................................................................................................................................4-31 Engine hood ...........................................................................................................................................4-33 Side doors ..............................................................................................................................................4-34 Rotary light cable ....................................................................................................................................4-35 Towing hole ............................................................................................................................................4-36 Cab protection (F.O.P.S.) .......................................................................................................................4-36 Load handling eyes ................................................................................................................................4-37 Windshield washer reservoir ..................................................................................................................4-38 Lower panels ..........................................................................................................................................4-38 Safety valves ..........................................................................................................................................4-38 Optional tool supply valves .....................................................................................................................4-39 Optional tool flow selector valve .............................................................................................................4-40 Fuel tank filler pump ...............................................................................................................................4-41 SECTION 5 - OPERATING INSTRUCTIONS ............................................................................................. 5-1 Before using the machine .........................................................................................................................5-1 Operating the machine .............................................................................................................................5-2 Run-in period ............................................................................................................................................5-3 Starting the engine ...................................................................................................................................5-4 Bringing the machine up to operating temperature ..................................................................................5-6 Engine operation ......................................................................................................................................5-7 Stopping the engine ..................................................................................................................................5-8 Operating the machine in cold weather ....................................................................................................5-9 Operating the machine in hot weather ......................................................................................................5-9 Machine operation ..................................................................................................................................5-10

TABLE OF CONTENTS Operating instructions (continued) Machine travel ........................................................................................................................................ 5-12 Transporting the machine ...................................................................................................................... 5-15 Handling the machine ............................................................................................................................ 5-20 Operating the machine in water ............................................................................................................. 5-21 Operating the machine on sloping ground ............................................................................................. 5-21 Parking the machine .............................................................................................................................. 5-22 Towing .................................................................................................................................................... 5-24 Operating the backhoe bucket ............................................................................................................... 5-25 Load handling ......................................................................................................................................... 5-26 Lowering the attachment in the event of a machine failure .................................................................... 5-28 Quick coupler installation ....................................................................................................................... 5-29 Quick tool installation and removal ........................................................................................................ 5-29 Auxiliary hydraulic circuits ...................................................................................................................... 5-34 SECTION 6 - SERVICING INTERVALS ..................................................................................................... 6-1 Servicing instructions ............................................................................................................................... 6-1 Hourmeter ................................................................................................................................................ 6-2 Daily inspections ...................................................................................................................................... 6-2 Quick coupler servicing instructions ......................................................................................................... 6-4 Quick coupler incorrect functioning .......................................................................................................... 6-4 Intervals .................................................................................................................................................... 6-5 SECTION 7 - LUBRICATION/FILTERS/FLUIDS ........................................................................................ 7-1 Fluids and Lubricants ............................................................................................................................... 7-1 Environment ............................................................................................................................................. 7-4 Fluid and lubricant capacities and specifications ..................................................................................... 7-4 Grease points ........................................................................................................................................... 7-5 Levels ..................................................................................................................................................... 7-12 Engine .................................................................................................................................................... 7-14 Cooling system ....................................................................................................................................... 7-17 Fuel system ............................................................................................................................................ 7-21 Releasing pressure in the hydraulic system ........................................................................................... 7-27 Hydraulic system .................................................................................................................................... 7-29 Air filter ................................................................................................................................................... 7-40 Swing reduction gear ............................................................................................................................. 7-46 Travel reduction gears ........................................................................................................................... 7-49 SECTION 8 - MAINTENANCE/ADJUSTMENTS ........................................................................................ 8-1 Tracks ...................................................................................................................................................... 8-1 Track rollers and idler wheels .................................................................................................................. 8-4 Radiator and oil cooler ............................................................................................................................. 8-5 Fan and alternator drive belt .................................................................................................................... 8-6 Fuel tank filter ........................................................................................................................................... 8-8 Adjusting rocker arm clearance ................................................................................................................ 8-8 Inspecting and cleaning the machine ....................................................................................................... 8-8

TABLE OF CONTENTS Maintenance/Adjustments (continued) Checking the machine settings .................................................................................................................8-8 Checking for cylinder leakage ..................................................................................................................8-9 Cab protection (F.O.P.S.) .........................................................................................................................8-9 Tooth tip wear limits on the backhoe bucket ..........................................................................................8-10 Replacing a tooth tip on a backhoe bucket .............................................................................................8-11 Replacing a backhoe bucket ..................................................................................................................8-12 Shimming the backhoe bucket ...............................................................................................................8-13 Fire extinguisher .....................................................................................................................................8-14 Welding on the machine .........................................................................................................................8-14 Checking the quick coupler latching hook opening ................................................................................8-15 Air conditioning .......................................................................................................................................8-17 Plastic and resin parts ............................................................................................................................8-20 Engine troubleshooting ...........................................................................................................................8-21 Hardware torque inspection ....................................................................................................................8-23 SECTION 9 - ELECTRICAL SYSTEM ........................................................................................................ 9-1 Fuses ........................................................................................................................................................9-1 Batteries ...................................................................................................................................................9-3 Alternator ..................................................................................................................................................9-7 Starter motor .............................................................................................................................................9-8 Replacing a bulb .......................................................................................................................................9-8 Adjusting the working lights ....................................................................................................................9-10 SECTION 10 - STORAGE ......................................................................................................................... 10-1 Storing the machine ................................................................................................................................10-1 SECTION 11 - SPECIFICATIONS ............................................................................................................. 11-1 Engine ....................................................................................................................................................11-1 Hydraulic system ....................................................................................................................................11-1 Undercarriage .........................................................................................................................................11-2 Safety devices ........................................................................................................................................11-2 Operator's compartment .........................................................................................................................11-3 Noise levels ............................................................................................................................................11-3 Vibration level inside the cab ..................................................................................................................11-3 Cab .........................................................................................................................................................11-3 Weights ...................................................................................................................................................11-3 Boom ......................................................................................................................................................11-4 Dippers ...................................................................................................................................................11-4 Backhoe buckets ....................................................................................................................................11-4 Dozer blade ............................................................................................................................................11-4 Machine overall dimensions ...................................................................................................................11-5 Working range ........................................................................................................................................11-7 Quick coupler ..........................................................................................................................................11-8 SECTION 12 - ALPHABETICAL INDEX ................................................................................................... 12-1

SECTION 1

4

TO THE OWNER HYDRAULIC CRAWLER EXCAVATOR CX225SR

CT02E021

1 Dealer's Stamp

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

1-1

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

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.

The standard attachments and tools of this machine are designed to carry out all kinds of earthmoving and rehandling operations. If you want to use this machine to handle a load (pipes, culverts, formwork, etc.), make sure that it is designed to carry out this kind of work. For this type of application, the machine must be equipped with safety valves, an overload indicator, a load handling chart corresponding to the type of machine and its attachment and a load fixing point. All legal requirements must also be strictly observed.

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

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

The machine must undergo regular inspections, the frequency of which varies according to the type of use.

Consult your CASE Dealer.

1-2

The engine and fuel system on your machine is 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!

Before permitting a new operator on this machine, make sure: 1. That the operator is qualified to operate the machine correctly and safely.

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

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

Make sure it is always complete and in good condition.

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

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.

SECTION 1 - TO THE OWNER OFFICIAL DOCUMENTS A certificate defining the weight shown on the manufacturer's plate: - Indication that the weight shown on the manufacturer’s plate is a value using the heaviest configuration and that it does not always correspond to the transport configuration.

A "EC" declaration of conformity: - For a new construction equipment machine, series produced to a type approved design, designed and manufactured in accordance with the requirements of European directive 98/37/EC, concerning machine safety and mainly: 1 - The following directives: - 89/336/EC: Electromagnetic compatibility - 2000/14/EC: Noise level (outside the cab) - 2006/42/EC: Noise level (inside the cab) 2 - The following European standards: - EN 474-1: Safety - General requirements - EN 474-5: Safety - Hydraulic excavators including load handling IMPORTANT: An original of this "EC" declaration is supplied with each machine and must be kept carefully by the owner.

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

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

A F

F

D

C

E

E

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

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

FRONT REAR RH SIDE LH SIDE TRAVEL MOTORS IDLER WHEELS

B CT02E022

2

1-3

SECTION 1 - TO THE OWNER

NOTES

1-4

SECTION 2

4

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

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

MACHINE

CT02C036

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

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

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

1

2

3

CT04A171B

2 ENGINE Make and type ............................... ISUZU AI - 4HK1X ........................................................................................

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

CT02E023

3

2-1

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

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

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

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

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

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

CAB PROTECTION (F.O.P.S.) (optional) Complies with ISO 10262 level 2 standard.

Identification number .....................................................

CD09C001

4 QUICK COUPLER (optional)

4

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

5

1

2

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

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

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

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

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

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

CS97A032C

7

6

3 5

2-2

SECTION 2 - IDENTIFICATION NUMBERS/MACHINE COMPONENTS DESCRIPTION OF THE MAIN COMPONENTS The CX225SR is a fully hydraulic excavator. It consists of an undercarriage fitted with tracks and a turntable bearing which supports the upperstructure frame. The upperstructure frame supports the attachment, at the front end of the machine, plus the engine, hydraulics and cab. When the operator works the controls, the engine-driven pump delivers hydraulic fluid to the control valves. The control valves distribute the hydraulic fluid to the various cylinders and motors concerned. A cooling system maintains the hydraulic fluid at normal operating temperature.

5 4 12 2

6

7

1 13

9

20

5 4

10

8 CT07M026

11

16

18

17

3

14

15

19 6

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

Cab/Operator's compartment Upperstructure Undercarriage Steps Access handles Boom Boom cylinders Dipper Dipper cylinder Backhoe bucket Backhoe bucket cylinder

12.

13.

14.

15.

16.

17.

18.

19.

20.

Engine compartment Counterweight Upper rollers Lower rollers Travel reduction gears Idler wheels Tracks Dozer blade (if equipped) Dozer blade cylinders (if equipped)

2-3

SECTION 2 - IDENTIFICATION NUMBERS/MACHINE COMPONENTS

NOTES

2-4

SECTION 3

26

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

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

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

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

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

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

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

CT02C003

1

3-1

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

2.

3.

4.

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

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

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

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

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

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

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

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

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

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

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

5.

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

19. Before parking the machine, make sure that the ground is stable. Plan the worksite so that the ground is flat, hard and level.

6.

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

7.

Remove any obstructions which hinder visibility.

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

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

8.

Make sure the windshield wiper works correctly.

9.

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

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

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

3-2

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

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

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

SECTION 3 - SAFETY/DECALS/HAND SIGNALS 24. Work out a means of convenient escape from the machine (emergency exit via the windshield or the rear window glass) in the event of the machine turning over or tipping over or the cab door being jammed.

5.

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

6.

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

More than 57 000 volts: 5 metres.

7.

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

8.

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

9.

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

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

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

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

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

QUICK COUPLER (optional) 1.

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

2.

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

Clean the locking system if necessary.

3.

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

Consult your CASE Dealer.

OPERATING THE MACHINE 1.

2.

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

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

3.

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

4.

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

10. Before operating the dozer blade (if equipped), make sure that there is no one in the working area of the latter.

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

12. 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.

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

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

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

15. Before tilting the seat back of the operator’s seat forward it is essential for the armrests to be in raised position to prevent them from fouling the control levers.

3-3

SECTION 3 - SAFETY/DECALS/HAND SIGNALS 16. In some configurations, the working range of the attachment allows the tool to interfere with the machine. Always maintain a safe minimum distance between the tool and the machine (swaying of the tool or incorrect operation).

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

Never forget this basic requirement.

PREVENTING RISKS CAUSED BY VIBRATIONS The machine's vibration affects the comfort and in some cases the health and safety of the operator. To reduce vibration risks to a minimum: 1.

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

18. Never leave the operator's compartment while the engine is running.

2.

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

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

3.

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

4.

Make sure that the operator's seat and is adjustment controls are in good condition and then adjust the seat to suit the operator's size and weight. The operator’s seat complies with the ISO 7096, 2000 standard, EM 6 class.

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

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

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

3-4

During work: 1.

Operate all controls gradually to ensure smooth machine operation.

2.

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

3.

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

4.

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

SECTION 3 - SAFETY/DECALS/HAND SIGNALS CAB PROTECTION (F.O.P.S.) (optional)

QUICK COUPLER (optional)

1.

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

1.

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

2.

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

2.

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

3.

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

4.

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

5.

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

3.

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

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

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

1.

Working area.

2.

Safety area.

2

1 CS97M019

2

USING AN IMPLEMENT OTHER THAN A BUCKET (optional) When using a special implement (hydraulic breaker, cutter crusher etc.), refer to the operator's manual provided with the implement.

IMPLEMENT OPERATION AND MAINTENANCE For the implement operation and maintenance, refer to the operator's manual provided with the implement.

3-5

SECTION 3 - SAFETY/DECALS/HAND SIGNALS PARKING THE MACHINE

6.

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

7.

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

When parking the machine, proceed as follows: 1.

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

2.

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

3.

Lower the dozer blade (if equipped) until it rests on the ground.

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

4.

Stop the engine and remove the starter switch key.

3. Lower the dozer blade (if equipped) until it rests on the ground.

5.

It is imperative to lift the LH control arm before leaving the operator’s compartment.

6.

Lock the cab door.

7.

Make sure that the hoods and doors are properly latched.

8.

1. Park the machine on flat, level ground.

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

5. Lock the tracks to prevent any machine movement.

8.

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

9.

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

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

MAINTENANCE AND ADJUSTMENTS 1.

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

2.

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

3.

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

Hydraulic oil escaping under pressure can cause serious injury.

4.

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

5.

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

3-6

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

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

11. Coolant solution is toxic.

Avoid contact with skin, eyes and clothing.

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

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

EYES: rinse thoroughly with water and seek medical advice.

SECTION 3 - SAFETY/DECALS/HAND SIGNALS 12. The pressure in the track tension cylinders is high.

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

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

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

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

QUICK COUPLER (optional) 1.

PREVENTING FIRES OR EXPLOSIONS 1.

Engine fuel can cause an explosion or a fire.

- Never refuel when the engine is running.

- Never smoke while refuelling.

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

2.

Always use a non-inflammable solvent for cleaning parts.

3.

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

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

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

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

4.

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

5.

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

6.

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

7.

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

8.

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

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

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

17. If the accumulator is not functioning correctly, consult your CASE Dealer. Never try to carry out any servicing operation on the accumulator. If this instruction is not followed serious injury can result.

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

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

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

Do not touch the controller or the injector.

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

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

Clean the locking system if necessary.

3-7

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

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

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

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

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

2.

When battery electrolyte is frozen, it can explode if you try to charge the battery or if you try to jump start the engine. To prevent the electrolyte from freezing, keep batteries fully charged at all times.

3.

Batteries give off explosive gases. Keep all naked flames, sparks and cigarettes away. Ensure adequate ventilation when charging batteries or when using in a confined place. Always protect your eyes when working near the batteries.

4.

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

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

5.

Never touch the battery terminals with hands, an electrolysis can occur inside the human body and damage your vital organs.

3-8

SECTION 3 - SAFETY/DECALS/HAND SIGNALS DECALS

!

!

WARNING

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

!

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

!

WARNING

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

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

POSITION OF DECALS See the "Illustration of decals" for the functions of decals.

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

3 8

1 9

4

12V

11

KHP1803-00

KHP12720-00

7

KHP11370-00

KHP1800-00

168840A1

ACTIVATE :A FUNCTION

AUX.CONTROL

ACTIVATE :B FUNCTION

KHP1484-00

2

24V KHP1804-00

6

12 5 10 CT07M001

3 3-9

SECTION 3 - SAFETY/DECALS/HAND SIGNALS When replacing a decal, make sure it is located as shown below.

22 13 14

30

30

15 28 17

16 27

25 24 29

20

19

21

18 23 26

CCT07M027

4

3-10

SECTION 3 - SAFETY/DECALS/HAND SIGNALS ILLUSTRATION OF DECALS TABLE OF SAFETY PRECAUTIONS Part number: KHP12720

1

A

B

CT07M003

C

D

KHP12720-00 0

E

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

A

CT07M004

6 MAINTENANCE OR INSPECTION This decal shows that the engine must be stopped and the starter key switch removed during maintenance or inspection of the machine.

B

CT06K006

7

3-11

SECTION 3 - SAFETY/DECALS/HAND SIGNALS DANGER ELECTRIC LINE This decal shows that work near overhead high-voltage electric lines must not be done without checking beforehand that all necessary measures have been taken to respect the minimum distances.

C

CT06K004

8 SEAT BELT This decal shows that the seat belt must always be fastened.

D

CT06K005

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

E

CS96D164

10 CONTROL LOCKING LEVER Part number: KHP1800

2

This decal shows that, before leaving the operator’s compartment, the control locking lever must be completely raised in order to prevent any movement of the machine.

KHP1800-00 CT07M005

11 3-12

SECTION 3 - SAFETY/DECALS/HAND SIGNALS WINDSHIELD LOCKING Part number: KHP12540

3

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

CT06K009

12 FUNCTION OF THE CONTROL LEVERS Part number: 161459A1

4

This decal shows the function of the left-hand and right-hand control levers.

CS00F530

13 FUNCTION OF THE LEVERS AND PEDALS Part number: KHP1498 (standard) KHP1484 (with right-hand option) KHP1510 (with left-hand option) KHP1572 (with dozer blade if equipped) KHP1573 (with option and dozer blade if equipped)

5

This decal shows the function of the travel control levers and pedals.

CS00E529

14 CIGARETTE LIGHTER SOCKET (24 Volts) Part number: KHP1804

6

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

24V

KHP1804-00

CT07M006

15 3-13

SECTION 3 - SAFETY/DECALS/HAND SIGNALS AUXILIARY SOCKET (12 Volts) Part number: KHP1803

7

This decal shows the location and voltage of the auxiliary socket that powers the 12 V electrical equipment.

It is strictly prohibited to connect devices of a different voltage.

12V

KHP1803-00

CT07M007

16 EMERGENCY EXIT Part number: KHP1247

8

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

CS98N560

17 POCKET FOR MAXIMUM HANDLING LIMITS TABLE

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

DOZER BLADE CONTROL LEVER FUNCTION (if equipped)

10

Part number: KHP0859 This decal shows the function of the dozer blade control lever.

CT02D266 CT02D266

18

3-14

SECTION 3 - SAFETY/DECALS/HAND SIGNALS TOOL INTERFERENCE (Monobloc boom) Part number: 168108A1

11

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

PDH0029

19 DOZER BLADE INTERFERENCE (if equipped) Part number: 168840A1

12

This decal draws attention to the fact that, in certain positions, there can be interference between the boom and the dozer blade. Always observe a minimum safety distance between the boom and the dozer blade (accidental movements).

168840A1

CT07K002

20 IT IS FORBIDDEN TO STAND WITHIN THE WORKING RANGE OF THE UPPERSTRUCTURE

13

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

CS95M062

21

3-15

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

14

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

CS95M063

22 SLINGING POINTS Part number: H7947565

15

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

PDE0768

23 HYDRAULIC RESERVOIR Part number: 168104A1

16

This decal shows the location of the hydraulic reservoir.

CS96D166

24 FUEL TANK Part number: KHP11700

17

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

CT06B013

25 3-16

SECTION 3 - SAFETY/DECALS/HAND SIGNALS ENGINE HOOD Part number: 168109A1

18

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

168109A1

CT07K018

26 ENGINE HOOD Part number: KHP12230

19

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

KHP12230-A

CT06K012

27 STARTING THE ENGINE Part number: 168110A1

20

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

CT07K017

28 RISK OF FALLING Part number: KHP12220

21

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

KHP12220-00

CT06K013

29 3-17

SECTION 3 - SAFETY/DECALS/HAND SIGNALS EXHAUST Part number: 168112A1

22

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

168112A1

CT07K019

30 RADIATOR Part number: 168101A1

23

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

CS96C179

31 FAN BELT Part number: 168111A1

24

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

CS96C038

32 INTERCOOLER (intermediate cooler) Part number: KHP12690

25

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

CT07A018

KHP12690-00

33 3-18

SECTION 3 - SAFETY/DECALS/HAND SIGNALS BATTERIES Part number: KHP12240

26

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

CT06K014

KHP12240-00

34 COMMON RAIL FUEL SYSTEM Part number: KHP13160

27

This decal shows that it is necessary to consult this manual before undertaking any maintenance operations on the fuel system at the engine (high pressure fuel system).

CT07G043

35 FILLING PUMP (if equipped) Part number: L2651565

28

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

PDF0357

36

3-19

SECTION 3 - SAFETY/DECALS/HAND SIGNALS NOISE LEVEL Part number: KHP1762

29

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

CS02E699

37 TIE-DOWN POINT Part number: KHP15190

30

This decal shows the tie-down points for transporting the machine.

CT08K003

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

CT02E037

39

3-20

SECTION 3 - SAFETY/DECALS/HAND SIGNALS BATTERIES This decal is on the batteries and draws attention to the risks and precautions to be taken when handling batteries.

CT10B001

40 QUICK COUPLER (optional) Part number: 84236228 This decal shows the precautions to be taken to ensure that the implement is correctly installed on the quick coupler.

CS01B501

41

3-21

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

START THE ENGINE

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

PDE0002A

42

PDE0003A

SHUT DOWN THE ENGINE

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

PDE0002

43 PDE0003

45

3-22

SECTION 3 - SAFETY/DECALS/HAND SIGNALS GO THIS FAR

EMERGENCY STOP Wave hands back and forth.

PDE0004A

46

PDE0005

ALL STOP AND HOLD

49 RAISE LOAD OR TOOL

PDE0004

47

PDE0006A

STOP

50

Wave one hand back and forth.

LOWER LOAD OR TOOL

PDE0005A

PDE0006

48

51

3-23

SECTION 3 - SAFETY/DECALS/HAND SIGNALS SLOWLY RAISE THE LOAD OR TOOL

TURN MACHINE RIGHT (swing load right) To stop movement, stop moving hand and clench fist.

PDE0007A

52

PDE0008

SLOWLY LOWER THE LOAD OR TOOL

55 RAISE TOOL

PDE0007

53

PDE0009A

TURN MACHINE LEFT (swing load left)

56

To stop movement, stop moving hand and clench fist.

PDE0008A

PDE0009

54

3-24

LOWER TOOL

57

SECTION 3 - SAFETY/DECALS/HAND SIGNALS LIFT BOOM

EXTEND DIPPER

PDE0010A

PDE0011

58 LOWER BOOM

61 FILL TOOL

PDE0010

PDE0012A

59 RETRACT DIPPER

62 EMPTY TOOL

PDE0011A

PDE0012

60

63

3-25

SECTION 3 - SAFETY/DECALS/HAND SIGNALS

NOTES

3-26

SECTION 4

42

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

1 CT02C030

1

2 CT02C031

2 The door can be latched in completely open position.

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

!

WARNING

3

!

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

!

WARNING

!

When seated in the operator’s compartment, with the engine running, make sure that you do not to operate the LH control lever inadvertently when unlocking the door. To prevent any incident, place the LH control arm in the raised position. See "Control locking lever".

!

WARNING

CT02C032

3

!

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

4-1

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

CT02E039

4 When alighting from or getting onto the machine, use the steps, the tracks and the access handles.

CT02E040

5

!

WARNING

!

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

!

WARNING

!

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

!

WARNING

!

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

!

WARNING

!

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

4-2

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

!

WARNING

!

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

11 8

2

14 10 1

12 9 11

7 4

13 3

6

5

4 7

11

CT02C282

6 1.

2.

3.

4.

5.

6.

7.

Operator's seat Control locking lever LH control lever Foot rest (pedal locked) Left-hand travel control pedal and lever Right-hand travel control pedal and lever Option pedals

8.

9.

10.

11.

12.

13.

14.

Instrument panel Heating, air-conditioning and option control RH control lever Air vents RH control arm LH control arm Dozer blade lever (if equipped)

4-3

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES RIGHT-HAND CONTROL ARM 1

6

2

4

3 CT02C046A

5 7

1. INSTRUMENT PANEL For more details, see the chapter "Instrument panel".

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

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

3. ENGINE THROTTLE BUTTON This button enables an increase or reduction in the engine speed. For "low idle" position, turn the button to the left. For "Maximum speed", turn the button to the right.

NOTE: If there is no change in engine speed, press and release the engine automatic idle speed selector (see item 4).

4-4

4. ENGINE IDLE SPEED SELECTOR This control enables automatic engine idle without operating the throttle button. For engine automatic idle, press and release the control and the engine will be in "Low Idle" position. Press once again on the control then release it, the engine returns to its initial speed.

5. MAXIMUM ATTACHMENT POWER CONTROL Located below the control lever, this control obtains maximum attachment power for about 8 seconds.

To do this, press and release the switch. To cancel, press and release the switch.

6. DOZER BLADE CONTROL LEVER (if equipped) This lever enables the operation of the dozer blade, see "Dozer blade control lever".

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES INSTRUMENT PANEL 1

4 CT02C046A

!

WARNING

!

The role of the instrument panel is to indicate the state of the machine and quickly warn the operator in case of any malfunction, through alarms. It should not be used for checking or maintenance.

The instrument panel is not waterproof. Make sure that it does not get wet.

1. FUEL LEVEL INDICATOR When the indicator needle moves close to the E zone, fuel needs to be added in the fuel tank. The indicator functions when the starter switch key is in the "Contact" position.

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

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

2. ENGINE COOLANT TEMPERATURE INDICATOR This indicator is divided into two zones: white zone, normal operating temperature and red zone: hot.

The indicator functions when the starter switch key is in the "Contact" position.

2

3

5 8 3. HOURMETER The hourmeter enables service operations to be scheduled. Its indications are similar to those of a watch when the engine is running. Its operation is indicated by the flashing of a green indicator lamp.

See section 6.

4. OVERHEATING INDICATOR LAMP (The audible warning device will sound) This indicator lamp shows that the engine coolant or hydraulic fluid temperature is abnormally high. Bring the engine to idle mode and reduce the water or fluid temperature. Check and clean the radiator.

5. ENGINE OIL PRESSURE INDICATOR LAMP (The audible warning device will sound) This indicator lamp lights up when the engine oil pressure is too low. If the indicator lamp lights up during operation, move the machine to a safe location, lower the attachment to the ground, shut down the engine and remove the starter switch key and determine the source of the malfunction.

IMPORTANT: If the needle is in the red zone, move the machine to a safe location, lower the attachment to the ground, shut down the engine and remove the starter switch key and check the cooling system to determine the source of the malfunction.

4-5

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES

6

7

8

9

10

11

12

13

CT02C046A

9 6. FUEL LEVEL INDICATOR LAMP (The audible warning device will sound) This indicator lamp lights up when the fuel level in the tank is too low, fuel must be added as soon as possible.

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

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

7. BATTERY CHARGE INDICATOR LAMP (The audible warning device will sound) This indicator lamp lights up when the alternator/fan belt is broken or when the alternator is not charging the battery any more. If the indicator lamp lights up during operation, move the machine to a safe location, lower the attachment to the ground, shut down the engine and remove the starter switch key and determine the source of the malfunction.

8. ENGINE ELECTRIC CIRCUIT INDICATOR LAMP (The audible warning device will sound) This indicator lamp lights up in case of failure of the engine electric circuit (short-circuit or disconnection). If the warning light comes on during operation, move the machine to a safe location, lower the attachment to the ground, shut down the engine, remove the starter switch key and check the engine electrical circuits.

4-6

9. PREHEATING INDICATOR LAMP (The audible warning device will sound) This indicator lamp lights up when the starter switch key is in the "ON" position and the temperature is low. Wait for the indicator lamp to go off before starting the engine.

10. WINDSHIELD WIPER SWITCH See "Windshield wiper switch" for its use.

11. WINDSHIELD WASHER SWITCH See "Windshield washer switch" for its use.

12. WORKING LIGHT SWITCH See "Working light switch" for its use.

13. HIGH SPEED TRAVEL SWITCH See "High speed travel switch" for its use.

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES LEFT-HAND CONTROL ARM 5

4

3

2

1 CT02C047B

10 1. HORN To sound the horn, press at the end of the LH control lever.

IMPORTANT: Always sound the horn before operating the machine.

2. CONTROL LOCKING LEVER The shape of the locking lever was designed to prevent the operator from leaving the operator’s compartment without having raised the lever beforehand. See "Control locking lever".

!

WARNING

!

4. ROTARY LIGHT (optional) This switch puts on or puts off the rotary light (optional). Press the switch, the rotary light and the indicator lamp light up. When the switch is pressed again, the rotary light goes out.

5. EMERGENCY SHUT DOWN SWITCH This switch shuts down the engine in case of an emergency. See "Shutting down the engine" in section 5.

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

To access or exit the operator’s compartment, the locking lever must be in the raised position. Never forget this basic requirement.

3. OVERLOAD INDICATOR SWITCH This two-position switch is to be used when handling loads. Place the switch in "ON" position. If the load to be lifted exceeds the authorized limit, the audible alarm will sound. In "OFF" (shut down) position the switch is non-operational. See "Load handling" in section 5.

4-7

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES

11

10

8

9

6 7

CT02C047B

11 6. HEATING AND VENTILATION CONTROL See "Heating and ventilation control" for its use.

7. HEATING, VENTILATION OR AIR-CONDITIONING CONTROL (optional) See "Heating, ventilation or air-conditioning control" for its use.

8. ECONOMY MODE SWITCH This switch selects the machine’s mode of operation.

In the "E" economy mode, work can be done at minimum cost with a lower fuel consumption.

The "N" normal mode is used for work in normal conditions.

The engine speed in "N" mode automatically goes to "E" mode if work is interrupted for 3 seconds. As soon as a control lever or a control pedal is operated, the engine speed automatically returns to "N" mode.

4-8

9. OPTION CONTROL (optional) This two-position switch enables the activation of options such as the hydraulic breaker, grab, shears, etc. Place the switch in one of the two positions depending on the accessories to be used. See "Auxiliary hydraulic systems" in section 5.

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

11. LOCATION OF OPTION CONTROL (optional)

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES WORKING LIGHT SWITCH This switch switches the working lights on or off. Press the button, the instrument panel as well as the working lights come on. Press the button again to switch them off.

CT02C053

12

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

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

CT02C054

13

WINDSHIELD WIPER SWITCH This switch has three positions: "Shut down", "Intermittent" and "Continuous". Press the switch for intermittent operation of the windshield wiper, the lamp (I) comes on. Press the switch again to obtain continuous operation of the windshield wiper, the lamp (II) comes on. Press the switch once more for the function to cease.

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

CT02C055

14

4-9

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES HIGH SPEED TRAVEL SWITCH When the switch is pressed, the travel speed goes from low to high. A red indicator lamp lights up when the travel is in high speed mode.

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

!

WARNING

!

If the travel speed is changed during travel, the machine may veer off course. Stop the machine before changing speeds.

CT02C056

15 Low speed: Suited for travel on a slope or on difficult terrain.

High speed: Suited for travel on level ground.

NOTE: As soon as the travel load becomes too great, the machine automatically returns to low speed.

4-10

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES HEATING AND VENTILATION CONTROL 5

2

3

7

6

4

1

CT02C057A

16 1. ON/OFF This push button (1) is for turning the system on or off.

5. AIR FLOW DIRECTION These push buttons (5) are used for the selection of three types of air flow direction.

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

- Via the top front air vent.

- Via the top front and rear air vents.

- Via the top and lower rear air vents.

2. (Not used) 3. VENTILATION These push buttons (3) allow the air flow to be increased or reduced. To increase the flow of air, press the top button. To decrease the flow of air, press the lower button. The segments increase or diminish depending on the flow selected.

4. TEMPERATURE These push buttons (4) help increase or reduce the temperature. To increase the temperature, press the RH button. To decrease the temperature, press the LH button. The temperature is controlled by the increase or reduction in the number of segments.

To select the type of air flow, press the button (5) relating to the type of air flow desired. Depending on the selected type, a built-in indicator lamp comes on.

6. WINDSHIELD DEFROSTER This button (6) allows the windshield to be defrosted. Press the button, windshield defrosting is carried out and a built-in indicator lamp comes on.

To stop, press the button again, the indicator lamp goes off.

7. AIR RECYCLING This button (7) allows two different types of air circulation to be selected.

- External air circulation.

- Internal air circulation.

Each time the button is pressed, the type of circulation will be changed. Depending on the selected type, a built-in indicator lamp comes on.

4-11

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES HEATING, VENTILATION OR AIR-CONDITIONING CONTROL (optional) 5

2

3

7

6

4

1

CT02D158A

17 1. ON/OFF This push button (1) is for turning the system on or off.

5. AIR FLOW DIRECTION These push buttons (5) are used for the selection of three types of air flow direction.

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

- Via the top front air vent.

- Via the top front and rear air vents.

- Via the top and lower rear air vents.

2. AIR-CONDITIONING SWITCH This switch (2) turns the air-conditioning on/off.

When it is on, the indicator lamp on the switch comes on.

3. VENTILATION These push buttons (3) 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 segments increase or reduce depending on the flow selected.

4. TEMPERATURE These push buttons (4) help increase or reduce the temperature. To increase the temperature, press the RH button. To decrease the temperature, press the LH button. The temperature is controlled by the increase or reduction in the number of segments.

To select the type of air flow, press the button (5) relating to the type of air flow desired. Depending on the selected type, a built-in indicator lamp comes on.

6. WINDSHIELD DEFROSTER This button (6) allows the windshield to be defrosted. Press the button, windshield defrosting is carried out and a built-in indicator lamp comes on.

To stop, press the button again, the indicator lamp goes off.

7. AIR RECYCLING This button (7) allows two different types of air circulation to be selected.

- External air circulation.

- Internal air circulation.

Each time the button is pressed, the type of circulation will be changed. Depending on the selected type, a built-in indicator lamp comes on.

4-12

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

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

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

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

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

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

1 CT02E078

18

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

CONTROL LOCKING LEVER The shape of the locking lever was designed to prevent the operator from leaving the operator’s compartment without having raised the lever beforehand.

The locking lever cancels the hydraulic controls.

In the raised position, all hydraulic controls are stopped.

The LH control arm is raised along with the locking lever for better access.

CT02C037

19 In the lowered position, all hydraulic controls are operational.

!

WARNING

!

To access or exit the operator’s compartment, the locking lever must be in the raised position. Never forget this basic requirement.

CT02C038

20

4-13

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES DIPPER AND UPPERSTRUCTURE SWING LH CONTROL LEVER

1

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

In the intermediate position both movements can be obtained simultaneously.

3

4

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

2 CT02C039A

21 1.

2.

3.

4.

The dipper extends.

The dipper retracts.

The upperstructure turns towards the left.

The upperstructure turns towards the right.

4

3

2

1

CS98M554

22

BOOM AND BUCKET RH CONTROL LEVER 5

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

7

8

6 CT02C040A

23 5.

6.

7.

8.

The boom lowers.

The boom raises.

The bucket retracts (filling).

The bucket extends (dumping).

6

5

8

7

CS98M554

24 4-14

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES TRAVEL CONTROL LEVERS AND PEDALS These levers and pedals are used to move the machine, see "Machine travel" in section 5.

NOTE: The forward or reverse travel speed depends on whether the high speed travel switch is used or not. See "High speed travel switch".

CT02C063

25

OPTION PEDAL This pedal is used for options such as hydraulic breakers, earth augers, etc. See "Auxiliary hydraulic circuits" in section 5.

IMPORTANT: Consult your CASE Dealer before mounting optional tools.

!

WARNING

!

This pedal has to be locked when the option is not used. See "Locking and unlocking the option pedal".

CT02E045

26

4-15

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES LOCKING AND UNLOCKING THE OPTION PEDAL UNLOCKING Push the locking pin forward.

CT02C044

27 LOCKING Pull down the locking pin into the pedal notch.

!

WARNING

!

This pedal has to be locked when the option is not used.

CT02C045

28

DOZER BLADE CONTROL LEVER (if equipped) This lever is used to operate the dozer blade.

1.

2.

Pull the lever, the dozer blade rises.

Push the lever, the dozer blade lowers.

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

NOTE: With the engine stopped, if the dozer blade is in the raised position, it is still possible to lower it using the control lever until it touches the ground.

!

WARNING

!

Before operating the dozer blade, make sure that there is no one standing in its working area.

CT02C041

29

4-16

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES CAB LIGHT Located on top of the cab on the LH side, the lighting is controlled by a switch built into the lamp bracket.

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

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

CT02C058

30

COAT HANGER HOOK The coat hanger hook is located on the rear LH cab upright.

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

CT02C059

31

REAR RH SIDE WINDOW To open the window, pull the handle backwards.

CT02C060

32 To close the window, bring the handle back towards the inside of the cab.

CT02C061

33 4-17

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES GLOVE COMPARTMENT The glove compartment is located on the RH side in front of the cab.

CT02C068

34

STORAGE TRAY The storage tray is located behind the operator’s seat.

CT02C069

35

ASHTRAY The ashtray is located on the RH side in front of the cab.

CT02C070

36

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

CT02C071

37 4-18

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES CAB RADIO COMPARTMENT This pre-fitted compartment is located on the rear righthand side of the operator's seat and is designed for a 24 volt car radio (optional).

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

CT02C072

38

SPEAKER COMPARTMENTS Located behind the cab, these compartments are designed for installing speakers for the cab radio.

CT02C073

39

FUSE BOX The fuse box is located on the rear RH side of the cab.

NOTE: To replace a fuse, see "Fuses" in section 9.

CT02C074

40

4-19

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

8

7 7

9

4 1 3

5

CT02E046

2

6 41

1.

2.

3.

4.

5.

Suspension adjustment Fore/aft adjustment Seat position adjustment Seat back angle adjustment Lumbar support adjustment

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

NOTE: The adjustment of the operator’s seat can only be carried out when the operator is seated in the seat, the engine is shut down and the starter switch key is set to "ACC" (accessory current supply).

4-20

6.

7.

8.

9.

Console and seat adjustment Armrest angle adjustment Headrest Seat belt

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES SUSPENSION ADJUSTMENT

1

Pull the handle (1) forward to decrease the rigidity of the suspension. Push the handle (1) back to increase the rigidity of the suspension.

CT02E047

42 FORWARD/REVERSE POSITION ADJUSTMENT Hold the control (2) in raised position, slide the seat to the required position and then release the control.

2

CT02E048

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

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

3 CT02E049

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

!

WARNING

4

!

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

CT02E050

45 4-21

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES LUMBAR SUPPORT ADJUSTMENT Use the inflation bulb (5) to inflate the lumbar support.

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

5

CT02E051

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

6 CT02E052

47 ARMREST ANGLE ADJUSTMENT Lift the armrests, turn the knob (7) to get the desired angle then lower the armrest.

7

CT02C082

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

8

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

CT02C083

49 4-22

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

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

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

!

WARNING

!

Always fasten your safety belt before starting the engine. The safety belt will protect you effectively.

The safety belt should not be too loose. It should not be twisted or caught in the operator’s seat.

9 CT02C084

50

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

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

4-23

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES WINDSHIELD

!

WARNING

!

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

OPENING 1.

Fold back the sunshield (1) against the windshield and pull the lever (2).

2

1 CT02C071

51 2.

Hold the upper (3) and lower (4) handles and carefully raise the windshield. Push to the rear until it engages.

3

CT02C086

52

4

CT02C087

53

4-24

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES 3.

Engage the RH latch (5) in the cab upright.

5

CT02C088

54 CLOSING 1.

Release the RH latch (5) from the cab upright.

5 CT02C089

55 2.

Hold the lower (4) and upper (3) handles and carefully lower the windshield. Make sure the window is completely down.

4

CT02C090

56

3

CT02C086

57 4-25

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES 3.

Make sure the top of the windshield is correctly latched.

CT02C091

58

LOWER FRONT WINDOW The lower front window may only be removed when the windshield is open.

1.

Pull the window upwards to remove it.

CT02C092

59 2.

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

CT02C093

60

4-26

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES WINDOW-BREAKER HAMMER Located on the RH cab upright, the window-breaker hammer is to be used to break the rear window in case of an emergency.

CT02C094

61

AIR VENTS The air vents (1) are located to the front and rear as well as under the operator's compartment, and allow the circulation and direction of air to be controlled. The air vents are opened and controlled manually.

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

1

CT02C095

62

1

CT02C085

63

1 CT02C096

64 4-27

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

CAB Two rear view mirrors at the front

CT02C097

65 One rear view mirror at the rear

CT02C099

66

4-28

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES UPPERSTRUCTURE Two rear view mirrors at the front

CT02C100

67 Two rear view mirrors at the rear

CT02C101

68

4-29

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES FUEL TANK Use suitable fuel, see "Fluids and lubricants" in section 7.

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

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

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

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

!

WARNING

!

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

Capacity of the tank: 265 litres.

Located on the RH side of the machine.

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

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

CT02E053

69

4-30

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES UPPER HOODS This hood gives access to the hydraulic tank and the fuel tank filler pump (optional).

To open it, pull the handle.

CT02E056

70 Lift the hood to the maximum so that it gets locked with the supporting prop.

CT02E057

71 To close, turn the support strut screw, then pull down and slam the hood.

CT02E057

72

4-31

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES This hood gives access to the swing reduction gear, to the Ultra Clean filter and to the coolant tank.

CT02E096

73 To open it, tilt the hood by means of the orifice until it touches the machine.

!

WARNING

!

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

CT02E097

74

4-32

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES ENGINE HOOD To open, pull the handle and lift the hood.

CT02E054

75 Lift the hood to the maximum so that it gets locked with the supporting prop.

To close, lift the hood slightly, pull back the supporting strut then lower the hood and slam it down to lock it.

Use the starter switch key to lock the hood.

!

WARNING

!

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

CT02E059

76

4-33

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES SIDE DOORS Use the outside handle to open the doors. To hold the doors, open, remove the struts from their storage position and install them in the holes provided. When closing, put the struts back into storage position.

LH REAR SIDE DOOR The door gives access mainly to the batteries, the air filter, etc.

CT02E055

77 RH REAR SIDE DOOR The door gives access to a number of hydraulic components (filters, etc.).

CT02E060

78 RH FRONT SIDE DOOR The door gives access to a number of hydraulic components.

CT02E061

79

4-34

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES

!

WARNING

!

Always install the struts when the doors are open.

!

WARNING

!

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

!

WARNING

!

Never leave tools or other objects behind the side doors.

ROTARY LIGHT CABLE Located in the battery compartment, this cable is designed to connect a 24 V rotary light (optional).

CT02E062

80

4-35

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES TOWING HOLE

!

WARNING

!

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

Located behind the undercarriage.

This hole is used to tow heavy objects (up to 10 tons), see "Towing" in section 5.

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

IMPORTANT: Towing must always be done in alignment with the undercarriage.

CT02C183

81

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

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

CT08K014

82

4-36

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

See "Load handling" in section 5.

IMPORTANT: This attachment point will only carry the load indicated in the maximum lift capacities table. See "Maximum lift capacities tables" in section 5.

CT02C184

83

!

WARNING

!

(If equipped) Never use the front or rear fixing points on the quick coupler to carry out load handling operations.

!

WARNING

!

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

!

WARNING

CT02C127

84

!

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

4-37

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES WINDSHIELD WASHER RESERVOIR Located inside the rear LH side door, this reservoir is equipped with an electric pump controlled by the windshield washer switch, see "Windshield washer switch".

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

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

CT02E063

85

LOWER PANELS Located under the upperstructure, these panels give access to several machine components.

IMPORTANT: Do not operate the machine if the panels have been removed.

!

WARNING

!

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

CT02E064

86

SAFETY VALVES (optional) SERVICE SPECIFICATIONS Check by your CASE Dealer ................................................................................................................. Every 6 months The role of the safety valve is to prevent lowering of the attachment caused by leaks in the control valve spool in the neutral position and the accidental rupture of a hose or a pipe and to ensure the gradual lowering of the attachment during these incidents.

CT02E065

87

4-38

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES OPTIONAL TOOL SUPPLY VALVES (optional) Located at the end on both sides of the dipper, these valves feed optional tools such as the hydraulic breaker, etc. These valves have two positions: open/closed.

CT02E067

88

CT02E066

89

4-39

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES OPTIONAL TOOL FLOW SELECTOR VALVE (optional) This valve is used to select the type of flow to be used depending on the tool installed on the machine.

IMPORTANT: Consult your CASE Dealer before mounting optional tools.

CT02C186

90 To access the valve, remove the upper plate.

CT02E068

91

4-40

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES FUEL TANK FILLER PUMP (optional)

!

WARNING

!

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

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

IMPORTANT: This pump is located in the front storage box and is to be used for fuel only. Use suitable fuel, see "Fluids and lubricants" in section 7.

1.

Park the machine on flat, horizontal ground. Stop the engine and turn the starter switch key to the "ON" position.

2.

Remove the filler cap from the fuel tank.

CT02E069

92 3.

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

1

PDF0361

93

4-41

SECTION 4 - CONTROLS/INSTRUMENTS/ACCESSORIES 4.

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

5.

Insert the output tube into the fuel tank.

PDF0362

94 6.

Tilt the switch (2) located on the pump to the "ON" (start) position, filling will begin.

7.

When the fuel tank is full, bring the switch (2) back to the "OFF" (shut down) position.

8.

Pour the residual fuel from the tubes into the drum, wipe and put the suction and output tubes back in place.

2

CT02E072

95 9.

Put the filler cap back on the fuel tank.

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

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

CT02E071

96 10. Turn the starter switch key to the "OFF" position (shut down).

NOTE: The pump (3) is equipped with a 10 amp fuse (4).

4

3

CT02E070

97 4-42

SECTION 5

38

OPERATING INSTRUCTIONS BEFORE USING THE MACHINE

!

WARNING

!

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

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

Check the level of all fluids (engine oil, hydraulic fluid and coolant) and make sure that the fluids and lubricants are suitable for prevailing conditions. See "Fluids and lubricants" in section 7 and "Operating the machine in cold weather".

2.

Carry out the daily maintenance operations. See section 6.

3.

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

4.

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

5.

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

6.

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

7.

Clean or replace any decals which are illegible.

See "Decals" in section 3.

8.

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

9.

Secure the cab door in either fully closed or fully opened position. See "Cab door" in section 4.

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

The operator must be alone on the machine.

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

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

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

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

10. Remove any obstructions which hinder visibility.

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

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

5-1

SECTION 5 - OPERATING INSTRUCTIONS OPERATING THE MACHINE

!

WARNING

!

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

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

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

2.

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

See section 6.

3.

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

4.

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

5.

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

6.

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

7.

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

8.

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

9.

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

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

5-2

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Frequently check the instruments on the instrument panel.

Check the oil levels and coolant solution level frequently.

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

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

(If equipped) Check the cab protective structure. See "Cab protection (F.O.P.S.)" in section 8.

AFTER THE FIRST 250 HOURS Replace the pilot circuit filter and the return filter. See "Hydraulic system" in section 7.

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

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

5-3

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

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

1.

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

2.

Make sure that the control locking lever is in the raised position.

Sound the horn before starting the engine.

CT02E073

1 3.

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

CT02C188

2 4.

Insert the starter switch key then turn the key to the "ACC" position, the red indicator lamps on the instrument panel remain illuminated. The audible alarm device will sound.

CT02C189

3

5-4

SECTION 5 - OPERATING INSTRUCTIONS 5.

Turn the starter switch key to the "ON" position and hold it there. The preheating indicator lamp comes on.

IMPORTANT: Do not keep the starter switch key in the preheating position for more than 6 seconds.

CT02D268

4 6.

Turn the starter switch key to the "START" position. Release the key as soon as the engine starts to turn. If the engine stops, wait about a minute and recommence the operation.

IMPORTANT: Do not operate the starter motor for more than 20 seconds at one time. Do not operate the starter motor when the engine is running.

IMPORTANT: When the engine is running, let it heat up until the low idle mode is steady.

IMPORTANT: When the engine is running, check the indicators and lights on the instrument panel regularly.

CT02C191

5 7.

Lower the control locking lever.

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

Starting this engine takes about 1 second before stabilisation.

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

When cold, the engine is at times difficult to start. But in all cases, do not operate the starter motor for more than 10 seconds.

CT02E074

6

5-5

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

After starting the engine and before using the machine, wait till the temperature of the hydraulic fluid reaches 20°C. CT02C193

7 BRINGING THE ENGINE UP TO OPERATING TEMPERATURE With the engine throttle button a quarter open, start the engine and allow it to run approximately for 5 to 10 minutes. When the coolant temperature increases, carry out the hydraulic fluid warm-up procedure.

CT02C188

8 HYDRAULIC FLUID WARM-UP Turn the engine throttle button to half-open position.

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

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

Repeat this operation of retraction and extension of the dipper until the temperature increases.

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

5-6

SECTION 5 - OPERATING INSTRUCTIONS ENGINE OPERATION

!

WARNING

!

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

!

WARNING

!

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

Do not touch the controller or the injector.

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

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

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

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

- There is no abnormal noise or vibration.

- There are no oil, fuel or water leaks.

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

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

Check the systems display and console regularly.

Stop the engine immediately if one of the following situations occurs: - Sudden increase or decrease in engine speed.

- Abnormal noise.

- Black smoke at the exhaust.

- Lighting up of oil pressure, battery, engine electrical circuit indicator lamps on the instrument panel during operation.

- Lighting up of the overheating indicator lamp on the instrument panel during operation.

5-7

SECTION 5 - OPERATING INSTRUCTIONS STOPPING THE ENGINE 1.

Lower the attachment and dozer blade (if equipped) until they are 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: In cold weather, let the engine run for about five minutes at idle speed.

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

CT02C194

9 3.

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

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

CT02C195

10 IN THE EVENT OF AN EMERGENCY In case of an emergency or when it is not possible to shut down the engine using the starter switch key, press the emergency "STOP" switch located on the LH control arm.

The engine shuts down, the audible alarm device sounds and the engine oil pressure, battery charge and engine electrical circuit indicators light up. Bring the starter switch key back to the "OFF" position.

To restart the engine, press again on the "STOP" switch then turn the starter switch key.

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

CT02C225

11

5-8

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

FUEL a) To prevent condensation forming and water getting into the fuel system, fill the fuel tank after each day's work and drain off any water before starting the next day's work. b) To prevent crystals forming at -2°C, use fuel which is rated for the ambient temperature or add an appropriate antifreeze to the fuel. See "Fluids and lubricants" in section 7.

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

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

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

OPERATING THE MACHINE IN HOT WEATHER Follow the recommendations made below: 1.

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

2.

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

3.

Test the radiator cap before hot weather starts.

Replace the cap as required.

4.

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

5.

Check the condition of the fan drive belt.

6.

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

7.

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

5-9

SECTION 5 - OPERATING INSTRUCTIONS MACHINE OPERATION OPERATING INSTRUCTIONS

!

WARNING

!

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

- Watch carefully and make sure you are aware of places where other people are working in your work area. Keep all other people away from the machine.

Serious injury can result if these instructions are not followed.

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

2) Excavation using the machine’s travel force.

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

- When ditching along the edge of a road, it may be necessary to change the attachment offset in relation to the machine. Check from time to time and correct if necessary.

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

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

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

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

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

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

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

More than 57 000 volts: 5 metres.

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

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

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

5-10

- When operating the attachment, take care that the bucket does not hit the dozer blade (if equipped).

- Take care not to hit the dozer blade (if equipped) against rocks.

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

- If the operation of the dozer blade (if equipped) is not necessary, always make sure that it is in the maximum raised position.

- During filling in operations, operate the two travel levers with your left hand while operating the dozer blade control lever (if equipped) with your right hand.

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

- Avoid turning the machine on steep slopes.

SECTION 5 - OPERATING INSTRUCTIONS - During digging with the dipper it may happen that the dipper stops in the vertical position (the load applied on the dipper and the bucket has reached its maximum value). The hydraulic circuit is unable to drive the cylinders to bear this load. This is a normal phenomenon and does not indicate any malfunction.

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

OPERATION 1.

Sit in the operator's seat and adjust it so that all the controls are readily accessible then fasten your safety belt.

2.

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

3.

Sound the horn.

4.

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

5.

Check all indicator lamps and gauges are operating correctly.

6.

Lower the control locking lever.

7.

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

5-11

SECTION 5 - OPERATING INSTRUCTIONS MACHINE TRAVEL

!

WARNING

!

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

IMPORTANT: Before any travel operation, raise the attachment and the dozer blade (if equipped).

NOTE: Travel speed depends on the tilting angle of the levers and the travel mode speed selected. See "High speed travel switch" in section 4.

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

CT07M028

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

CS98M546

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

CS98M547

14

5-12

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

CS98M548

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

CS98M551

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

CS98M549

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

CS98M550

18 5-13

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

CS98M552

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

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

CS98M553

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

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

CS98M545

21

5-14

SECTION 5 - OPERATING INSTRUCTIONS TRANSPORTING THE MACHINE IMPORTANT: For transporting the machine without attachment, the counterweight must be removed, consult your CASE Dealer.

REMOVING THE ATTACHMENT FROM THE MACHINE The use of lifting systems is necessary for removal and installation of the machine attachment and counterweight. Refer to the Service Manual or consult your CASE Dealer.

!

WARNING

!

First of all, assign a person as supervisor to direct the operation and agree on the safety measures, procedures and suitable hand signals.

!

WARNING

!

The use of lifting systems must be entrusted to qualified personnel. The operators and all the personnel assigned to this operation must be perfectly aware of the procedures to be followed.

Make sure that the devices and lifting cables are in good condition.

!

WARNING

!

WARNING

!

Before removing the attachment from the machine, make sure that the air pressure and hydraulic oil pressure are at zero.

!

WARNING

!

Prevent dust and contamination entering open circuits. Any contamination of circuits can cause malfunction of the machine.

!

Since this operation may be dangerous, you are advised to wear suitable clothing and to respect the relevant safety measures.

5-15

SECTION 5 - OPERATING INSTRUCTIONS

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

ON A TRAILER

!

WARNING

!

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

!

WARNING

!

It is mandatory to remove the counterweight before transporting the machine without the attachment. Consult your CASE Dealer.

Make sure you know the safety rules and regulations before transporting the machine. Make sure both trailer and machine are fitted with the right safety equipment.

LOADING 1.

Place a block behind the trailer wheels. Install the trailer side extensions (if equipped).

CT02C196

22 2.

Select the engine auto idle function on the RH control lever.

CT02C040A

23

5-16

SECTION 5 - OPERATING INSTRUCTIONS 3.

Make sure that the high speed travel switch is inactive.

CT02C056

24 4.

Raise the dozer blade (if equipped).

CT02C197

25 5.

(Machine with attachment)

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

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

NOTE: If the machine is equipped with a dozer blade, it is preferable to load the machine with the dozer blade facing the trailer to prevent interference with the attachment.

PDH0248

26 5.

(Machine without attachment)

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

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

CS99B518

27 5-17

SECTION 5 - OPERATING INSTRUCTIONS 6.

(Machine with attachment)

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

PDH0250

28 7.

(Machine with attachment)

Place the machine completely in front of the trailer so that the attachment and the dozer blade (if equipped) rest on the floor of the trailer.

PDH0251

29 7.

(Machine without attachment)

Place the machine completely in front of the trailer, rotate the upperstructure then place the dozer blade (if equipped) on the floor of the trailer.

CS99B519

30 8.

Shut down the engine, remove the starter switch key, raise the control locking lever.

9.

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

10. Fold the rear view mirrors inwards.

CT02E073

31 5-18

SECTION 5 - OPERATING INSTRUCTIONS 11. Use blocks and chains to fasten the machine and the attachment (if equipped) to the trailer.

PDF0360

32 12. Measure the distance between the ground and the highest point of the machine. You must know the overall height. See "Machine overall dimensions" in section 11.

PDH0251

33 UNLOADING 1.

Remove the blocks and fastening chains.

2.

Start the engine.

3.

Lower the control locking lever and raise the dozer blade (if equipped).

4.

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

5.

Move slowly while raising the attachment (if equipped) so as to maintain it a few centimetres above the ground.

6.

Turn the rear view mirrors back to their correct position.

7.

(Machine without attachment) Install the attachment and the counterweight.

IMPORTANT: When the attachment has been installed, all air must be removed from the hydraulic circuit and the machine must be tested for correct operation. Do not forget to check the oil level.

5-19

SECTION 5 - OPERATING INSTRUCTIONS HANDLING THE MACHINE Retract the attachment, bucket and dipper cylinders fully extended then place the attachment on the ground. Shutdown the engine and leave the operator’s compartment.

30˚ - 40˚

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

See "Weight" in section 11.

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

CT08K001

34

!

WARNING

!

60°

The machine must be handled very slowly and horizontally.

!

WARNING

!

First of all, assign a person as supervisor to direct the operation and agree on the safety measures, procedures and suitable hand signals.

!

WARNING

!

The use of lifting systems must be entrusted to qualified personnel. The operators and all the personnel assigned to this operation must be perfectly aware of the procedures to be followed.

Check the lifting devices and cables and make sure that they are in good condition, suitable for lifting the load to be handled and fitted with safety type hooks that will not accidentally open.

!

WARNING

!

Since this operation may be dangerous, you are advised to wear suitable clothing and to respect the relevant safety measures.

!

WARNING

!

Make sure that there is nobody within the working area during handling operations.

5-20

= CT08K002

= 35

SECTION 5 - OPERATING INSTRUCTIONS OPERATING THE MACHINE IN WATER 1.

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

2.

Only the undercarriage must be below water level.

The maximum water level can be up to the height of the tracks.

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

3.

Before immersing the machine, inject a generous amount of new grease into the attachment linkages and the dozer blade (if equipped), the turntable and its teeth.

CT02E075

36

IMPORTANT: Do not operate in a fast flowing stream.

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.

!

WARNING

!

Before parking the machine, make sure that the ground is stable. Plan the worksite so that the ground is flat, hard and level.

- During hillside operations, be extra careful.

- Make sure that the low speed travel is selected.

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

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

5-21

SECTION 5 - OPERATING INSTRUCTIONS PARKING THE MACHINE 1.

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

2.

Place the upperstructure in line with the undercarriage.

3.

Retract and position the attachment in the shaft of the undercarriage then dig the bucket into the ground and lower the dozer blade (if equipped) to the ground.

4.

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

CT02C194

37 5.

Shut down the engine and remove the starter switch key.

CT02C195

38 6.

Raise the control locking lever.

CT02E073

39

5-22

SECTION 5 - OPERATING INSTRUCTIONS 7.

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

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

!

WARNING

!

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

CT02C187

40

5-23

SECTION 5 - OPERATING INSTRUCTIONS TOWING IMPORTANT: Towing must always be done in alignment with the undercarriage.

!

WARNING

!

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

!

WARNING

!

The 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.

!

WARNING

!

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

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

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

If the machine is bogged down for example, it must be towed as follows: 1.

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

2.

Attach the shackles, chains and tackle to the undercarriage taking care to protect any salient angles.

Pull the machine without jerking, very slowly and in alignment with the undercarriage.

CT008K010

41

5-24

SECTION 5 - OPERATING INSTRUCTIONS TOWING A LOAD To tow a load of up to 10 tons, use the towing hole provided for this purpose. See "Towing hole" in section 4.

CT008K011

42

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

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

EXCAVATING METHOD

PDH0493M

43

1

2

3

PDH0494M

44 1.

2.

3.

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

5-25

SECTION 5 - OPERATING INSTRUCTIONS LOAD HANDLING

!

WARNING

!

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

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

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

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

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

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

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

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

- Place the overload indicator switch on the left-hand control arm in "ON" (running) position. This is mandatory. See "Left-hand control arm" in section 4.

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

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

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

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

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

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

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

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

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

5-26

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

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

IMPORTANT: Maintain this position throughout the load handling operation.

CT02J046

45 2.

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

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

NOTE: The quick coupler eye can be used for handling loads up to 10 tonnes.

1

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

CT02J047

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

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

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

IMPORTANT: The weight of the quick coupler (optional) has to be subtracted from the given values.

See "Weights" in section 11.

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

CT02E076

47

5-27

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

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

CT02D268

48 2.

Lower the control locking lever.

CT02E074

49 3.

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

CT02E077

50

5-28

SECTION 5 - OPERATING INSTRUCTIONS QUICK COUPLER INSTALLATION (optional)

!

WARNING

!

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

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

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

1

1

CT02C204

51

QUICK TOOL INSTALLATION AND REMOVAL (optional) IMPORTANT: This quick coupler is designed to be used with CASE buckets. This being said, other buckets may be used, provided the diameter of the pins and the width between the bucket lugs are modified to meet the dimensions needed to fit the quick coupler (pins, washers, bushings, etc.). Consult your CASE Dealer.

!

WARNING

!

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

5-29

SECTION 5 - OPERATING INSTRUCTIONS INSTALLATION 1.

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

2.

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

CT02E078

52 3.

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

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

CT02C205

53 4.

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

2 1

CT02C206

54

5-30

SECTION 5 - OPERATING INSTRUCTIONS 5.

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

CT02C207

55 6.

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

CT02C208

56 7.

Place the switch in the locked position, the audible alarm device will cease functioning.

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

CT02E078

57 8.

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

CT02C209

58 5-31

SECTION 5 - OPERATING INSTRUCTIONS 9.

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

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

CT02C210

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

CT02C211

60 DISASSEMBLY 1.

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

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

CT02C208

61

5-32

SECTION 5 - OPERATING INSTRUCTIONS 2.

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

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

CT02E078

62 3.

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

CT02C215

63 4.

Operate the dipper control to unhook the tool.

CT02C216

64

5-33

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

Consult your CASE Dealer in order to adjust the pressure and the flow required for the use of the option correctly.

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

CONFIGURING THE HYDRAULIC BREAKER, CUTTER CRUSHER TO A FLOW OR BUCKET 1.

Make the necessary tool connections and then, using a hexagonal wrench, open the supply valves located at the tip of the dipper, LH and RH side.

CT02C287

65 2.

Remove the 4 screws (1) then the plate (2).

2

1 CT02E068

66

5-34

SECTION 5 - OPERATING INSTRUCTIONS 3.

Remove the screw (1) then bring the flow selector valve to position (B), reinstall the screw (1) in position (B).

1

B CT02C186

67 4.

Make sure that the switch (1) located on the LH control arm is in the desired position.

1

CT02E081

68 5.

Operate the option pedal. See "Option pedal" in section 4.

CT02E045

69 6.

When removing the hydraulic breaker, turn the supply valves to the closed position (-), and plug them.

CT02C124

70 5-35

SECTION 5 - OPERATING INSTRUCTIONS TWO FLOW CUTTER CRUSHER CONFIGURATION 1.

Make the necessary tool connections and then, using a hexagonal wrench, open the supply valves located at the tip of the dipper, LH and RH side.

CT02C287

71 2.

Remove the 4 screws (1) then the plate (2).

2

1 CT02E068

72 3.

Make sure that the flow selector valve is in position (C). If necessary, put it in position.

C CT02D066A

73

5-36

SECTION 5 - OPERATING INSTRUCTIONS 4.

Make sure that the switch (1) located on the LH control arm is in the desired position.

1

CT02E082

74 5.

Operate the option pedal. See "Option pedal" in section 4.

CT02E045

75 6.

When removing the cutter crusher, turn the supply valves to the closed position (-), and plug them.

CT02C124

76

5-37

SECTION 5 - OPERATING INSTRUCTIONS 7.

Toggle the switch to the bucket position.

CT02E081

77 8.

Remove the screw (1) then bring the flow selector valve to position (B), reinstall the screw (1) in position (B).

1

B CT02C186

78

5-38

SECTION 6

8

SERVICING INTERVALS SERVICING INSTRUCTIONS Respect the maintenance intervals by checking the hourmeter every day. Before starting maintenance, park the machine on flat, firm ground, away from any obstacles, with the dipper retracted and the bucket on the ground. Unless otherwise specified, all maintenance operations must be carried out with the engine stopped, and the key removed from the starter switch.

It is preferable to wait for all circuits to cool down before starting work.

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

Wear suitable clothing and remember to use the necessary safety equipment.

!

WARNING

!

There is a risk of serious injury if maintenance or repairs are not carried out correctly. If you do not understand maintenance procedures, consult your CASE Dealer.

!

WARNING

!

If the attachment is raised or if the machine moves without an operator, serious injury can result.

Before performing any maintenance, proceed as follows: 1. Park the machine on flat, level ground.

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

3. Lower the dozer blade (if equipped) until it rests on the ground.

4. Shut down the engine and remove the starter switch key.

5. Lock the tracks to prevent any machine movement.

!

WARNING

!

Be sure all the service operations in this section are carried out punctually at the intervals given, in order to ensure optimum performance levels and maximum safety when using the machine.

When carrying out service work on the machine, place a "Do not operate" tag on the instrument panel. Never climb down from the operator's compartment leaving the engine running.

Remove the necessary lower panels during maintenance of certain machine components.

!

WARNING

!

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

Any modification to this machine without prior authorization could cause serious injury. Do not make any modifications without authorization. Consult your CASE Dealer.

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

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

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

6-1

SECTION 6 - SERVICING INTERVALS HOURMETER The hourmeter enables service operations to be scheduled. Its hourly indications are the same as those of a clock when the engine is running.

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

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

CT02C243

1

DAILY INSPECTIONS

UPPERSTRUCTURE

Every day, before starting work, it is necessary to inspect the machine and service certain of its components.

- Check the fuel tank level.

GENERAL REMARKS

- Check the hydraulic reservoir level.

- Check that the hydraulic oil is clean.

- Check signs of leaking oil or water.

- Check the components for signs of leaking oil or water.

- Check that all screws and nuts are correctly tightened.

- Check the condition of all lines.

- Wipe off any dust (engine, operator's compartment etc.).

- Check for any signs of damage.

ENGINE - Check the oil level and change the oil if necessary.

- Check the coolant level.

- Check the radiator for signs of clogging or deterioration.

- Check the radiator fan belt tension.

- Check the air filter is clean and not restricted.

- Check the components for signs of leaking oil or water.

- Check the condition of all lines.

6-2

- Make sure there are no electrical short circuits.

- Check the battery connections are properly tightened.

- Adjust the rear view mirrors.

UNDERCARRIAGE - Check the pad hardware.

- Check the condition of the tracks.

- Check that the upper and lower track rollers and the idler wheels are not leaking oil.

ATTACHMENT - Check the cylinders are not leaking oil.

- Check the condition of all lines.

- Check the condition of the bucket teeth.

SECTION 6 - SERVICING INTERVALS AFTER STARTING THE ENGINE - Did the engine start correctly? Are the exhaust fumes normal? Any strange noises?

- Check for abnormal noise on the hydraulic components.

- Check the components for signs of leaking oil or water.

- Check the audible alarm devices, working lights and windshield wipers.

- Check that all circuits (travel, swing and tool) are functioning correctly.

IMPORTANT: If the slightest defect is found, repair it immediately before using the machine or consult your CASE Dealer.

6-3

SECTION 6 - SERVICING INTERVALS QUICK COUPLER SERVICING INSTRUCTIONS (optional) EVERY DAY AND BEFORE EACH INSTALLATION OF THE QUICK COUPLER Check that the locking bar functions correctly and that it is not fouled by foreign matter.

Check the quick coupler cylinder hoses for free movement.

Check the return spring and its mounting hardware.

Check for any signs of cracks.

!

WARNING

!

There is a risk of serious injury if maintenance or repairs are not carried out correctly. If you do not understand maintenance procedures, consult your CASE Dealer.

CT02C242

Modification of the quick coupler without prior authorization can cause serious injury. Do not carry out any modification without authorization. Consult your CASE Dealer.

IMPORTANT: If you use your quick coupler under particularly severe conditions (with a hydraulic breaker or in a corrosive environment, etc.) the servicing and inspection intervals must be reduced.

QUICK COUPLER INCORRECT FUNCTIONING (optional) IMPORTANT: Make sure that the attachment is in full contact with the ground before carrying out the following checks.

If the quick coupler does not work correctly, check the following items: - That no pin is broken, bent or lost.

- That no foreign matter is fouling the safety device.

- The condition of the return spring.

- That the cylinder is not damaged or bent.

- That there are no leaks from hydraulic hoses, etc.

If the problem persists after all these checks, consult your CASE Dealer.

6-4

2

SECTION 6 - SERVICING INTERVALS

7-14

Engine oil level

1

10 (F)

7-17

Coolant level

1

10 (F)

7-21

Drain fuel tank sediment

1

7-29

Hydraulic reservoir level

1

8-5

Radiator and oil cooler

1

8-6

Fan/alternator belt

1

10 (F)

Bucket quick coupler (optional)

4

(Q)

7-10

Dozer blade (if equipped)

6

7-29

Hydraulic system lines

-

8-17

Air-conditioning air inlet filter (optional)

1

50

5000

8-17

Air-conditioning air recycling filter (optional)

1

50

5000

7-5

Boom cylinder bottom

2

250

7-5

Boom cylinder top

2

250

7-5

Dipper cylinder bottom

1

250

7-5

Dipper cylinder top

1

250

7-5

Bucket cylinder bottom

1

250

7-5

Bucket cylinder top

1

250

7-9, 8-15

DRAIN BLEED

GREASE

CHECK

REPLACE

INTERVALS IN HOURS CLEAN

SERVICE POINTS

NO. OF POINTS

PAGE

INTERVALS

10 (F) 10 (F) 500

10 (F) 50 50 50

7-5

Dipper/bucket linkage

5

7-17

Tightening of clamps and radiator hoses

-

250

7-21

Fuel pre-filter filter element

1

7-29

Drain hydraulic reservoir sediment

1

7-41

Primary air filter element

1

7-46

Swing reduction gear oil level

1

250

7-49

Travel reduction gears oil level

2

250

8-1

Pad screw torque

-

250 (G)

8-4

Idler wheel and rollers

-

250

8-6

Fan/alternator belt tension

1

250

250 (B) 250 250 250 (H)

1000 (J)

250 (H)

8-9

Cab protection (optional)

1

250 (G)

8-23

Screw and nut tightening torque

-

250 (G)

9-3

Battery charging state

2

250 250

9-3

Batteries electrolyte level

2

7-10

Turntable bearing

2

500

7-11

Turntable bearing teeth

1

500

7-14

Engine oil

1

7-14

Engine oil filter

1

500

7-21

Fuel filter filtering element

1

500

500

6-5

DRAIN BLEED

GREASE

CHECK

7-5

Boom/dipper shaft

2

1000 (T)

7-5

Boom bottom

3

1000 (T)

8-8

Rocker arm clearance

-

7-17

Cooling system

1

7-29

Hydraulic fluid condition

-

7-29

Hydraulic reservoir breather filter element

1

1000

7-41

Secondary air filter element

1

1000 (D)

7-46

Swing reduction gear draining

1

1000 (L)

7-49

Travel reduction gears draining

2

1000 (L)

9-7

Alternator

1

1000 (K)

9-8

Starter motor

1

1000 (K)

7-11

Swing reduction gear

1

7-29

Pilot filter (*)

1

7-29

Inlet filter

1

1000 (K) 1000 (C) 1000

2000 2000 (L) 2000

5000

1

2000 (L) (U)

Hydraulic hoses

-

4000 (E)

Hydraulic fluid (*)

1

5000

7-21

Fuel pre-filter bleed

1

(A)

7-21

Fuel filter bleed

1

(A)

7-21

Fuel supply pump filter

1

(N)

8-1

Tracks

2

(M)

8-1

Track tension

2

8-8

Fuel tank filter

1

(N)

8-8

Machine inspection

1

(N)

8-8

Machine settings

-

(V)

7-29

Return circuit filter (*)

7-29 7-29

(N) (N)

8-9

Cylinders

-

(S)

8-14

Fire extinguisher

1

(P)

8-17

Air conditioning (optional)

1

(R)

(A) When the float reaches the level line (A).

(B) Or every 6 months.

(C) Or every 2 years or twice a year (autumn/spring) if anti-freeze is used.

(D) Or after the primary filter has been cleaned 3 times.

(E) Or every 2 years, whichever comes first.

(F) Or every day.

(G) After the first 50 hours during the run-in period.

(H) Or when central zone of the clogging indicator turns red.

(J) Or after cleaning 6 times.

6-6

REPLACE

INTERVALS IN HOURS CLEAN

SERVICE POINTS

NO. OF POINTS

PAGE

SECTION 6 - SERVICING INTERVALS

SECTION 6 - SERVICING INTERVALS (K) Have it checked by your CASE Dealer.

(L) After the first 250 hours during the run-in period.

(M) Periodically and when the machine has been working in mud.

(N) Periodically.

(P) Check once a month and have it checked every 6 months by a specialist.

(Q) Every week and whenever installing the quick coupler.

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

(S) Check for leaks.

(T) If all these linkage points are not equipped with genuine parts, these points must be greased every 50 hours.

(U) If biodegradable fluid is used, it is imperative for the servicing interval to be reduced to 1000 hours.

(V) Have this checked every 6 months by your CASE Dealer. (*) IMPORTANT: If the machine is equipped with a hydraulic breaker, it is imperative that the servicing intervals are reduced, see "Replacing the hydraulic filters and fluid when a hydraulic breaker is used" in section 7.

6-7

SECTION 6 - SERVICING INTERVALS

NOTES

6-8

SECTION 7

50

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

!

WARNING

!

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

TRANSMISSION COMPONENT OIL Extreme pressure oil used for enclosed transmission components.

CASE/AKCELA: GEAR 135H EP (SAE 80W-90. API GL 5. MIL-L-2105 D. MS 1316.

ZF TE-ML 05A) GREASE

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

CASE/AKCELA: MULTIPURPOSE GREASE 251H EP (NLGI 2) "Extreme Pressure" multipurpose grease with lithium soap and calcium.

Temperate climates -20°C to +40°C CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID (MS 1230. ISO VG 46. DIN 51524 PART 2 HV) Hot climates 0°C to +50°C CASE/AKCELA: AW HYDRAULIC FLUID 68 HV (MS 1216. ISO VG 68. DIN 51524 PART 3 CATEGORY HVLP) Cold climates -25°C to +20°C CASE/AKCELA: AW HYDRAULIC FLUID 32 (MS 1216. ISO VG 32. DIN 51524 PART 2) Biodegradable fluid: -30°C to +40°C This yellow-coloured fluid is miscible with standard fluid. If used to change standard fluid, it is advisable to drain the circuit completely before refilling with this fluid.

CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID BIO (MS 1230. ISO VG 46. DIN 51524 PART 2 HV)

7-1

SECTION 7 - LUBRICATION/FILTERS/FLUIDS ENGINE OIL The CASE/AKCELA "No. 1 ENGINE OIL" is recommended for your engine. This oil ensures correct lubrication of your engine in all working conditions.

If the CASE/AKCELA Multigrade "No. 1 ENGINE OIL" cannot be obtained, use the oil corresponding to one of the following categories: ACEA E7. API CI-4.

CP02N001

1 OIL RANGE

1 2 2 3 3

CT02M001

2 (1) With mineral base (2) With semi-synthetic base (3) With synthetic base

7-2

SECTION 7 - LUBRICATION/FILTERS/FLUIDS FUEL The fuel used must comply with the Tier 3 emission control regulations.

Use grade No. 2-D fuel. The use of other types of fuel can result in a loss of power of the engine and may cause high fuel consumption.

In cold weather (below -7°C), it is provisionally approved to use a mixture of fuels No. 1-D and No. 2-D. Consult your fuel supplier or your CASE Dealer.

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

Conditions applicable to diesel fuel The diesel fuel used must: -

be free from dust particles, even minute ones, have the proper viscosity, have a high cetane number, present great fluidity at low temperatures, have low sulphur content, have very little residual carbon.

Recommendations applicable to diesel fuel - JIS (Japanese Industrial Standard): No. 2 - DIN (Deutsche Industrie Normen): DIN 51601 - SAE (Society of Automotive Engineers) according to SAE-J-313C: No. 2-D - BS (British Standard) according to BS/2869-1970: Class A-1 - EN 590 - or fuel corresponding to these standards and stipulated in your country.

Using fuels other than those recommended can damage the fuel injection pump, the injector and other parts of the fuel supply system and the engine. The CASE company disowns any responsibility concerning this kind of damage, which is not covered by the guarantee. To avoid any damage to the engine fuel supply system, you are recommended to take the following safety messages into account: - Certain fuel suppliers mix used engine oil with diesel fuel.

Certain manufacturers of large engines allow them to do this. However, for your engine, do not use diesel fuel contaminated by engine oil. In addition to damaging the engine, this fuel can actually adversely affect the correct purification of exhaust gases. Before using diesel fuel, ask the supplier to confirm that it meets the above specifications.

IMPORTANT: For a proper use of fuel additives consult your supplier or your CASE Dealer. Do not inject fuel oil or gasoline, both fuels can damage the engine.

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

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

The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible.

Drain off water and impurities regularly.

IMPORTANT: It you use fuel which has a sulphur content of more than 2500 ppm, use API grade CF-4 or JASO grade DH-1 engine oil. However, if these specifications cannot be met, it is imperative that the engine servicing intervals are reduced to 250 hours (oil change, filters etc.). Every 3000 hours, the injectors and EGR (Exhaust Gas Recirculation) circuit parts must be checked and replaced by your CASE Dealer.

IMPORTANT: Use of any other fuel can cause serious breakdown and will cancel the guarantee.

7-3

SECTION 7 - LUBRICATION/FILTERS/FLUIDS ANTI-FREEZE/ANTI-CORROSION

ENVIRONMENT

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

CASE/AKCELA: PREMIUM ANTI-FREEZE (MS 1710)

Before carrying out any maintenance operation on this machine and before disposing of used fluids or lubricants, always think of the environment. Never throw oil or fluid on the ground and never place it in leaking receptacles.

For areas where the temperature goes down to -38°C, mix 50/50 with water.

IMPORTANT: Do not mix products of a different origin or brand.

The same product must be used when topping up the system.

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

FLUID AND LUBRICANT CAPACITIES AND SPECIFICATIONS ENGINE Type of oil............................................................................................................................. "No. 1 ENGINE OIL" Capacity (with filter change) ............................................................................................................................ 23.1 litres COOLING SYSTEM System capacity............................................................................................................................................... 25.6 litres FUEL SYSTEM Tank capacity .................................................................................................................................................... 265 litres HYDRAULIC SYSTEM Type of fluid.................................................................................................. "HYDRAULIC EXCAVATOR FLUID" Total system capacity........................................................................................................................................ 205 litres Reservoir capacity ............................................................................................................................................ 120 litres TRAVEL REDUCTION GEARS Type of oil................................................................................................ "GEAR 135H EP" extreme pressure oil Capacity (per reduction gear)............................................................................................................................ 4.7 litres SWING REDUCTION GEAR Type of oil................................................................................................ "GEAR 135H EP" extreme pressure oil Capacity ................................................................................................................................................................ 5 litres Type of grease................................................................................................................................ "GREASE 251H EP" Capacity ................................................................................................................................................................. 0.6 kg TURNTABLE TEETH Type of grease................................................................................................................................ "GREASE 251H EP" Capacity .................................................................................................................................................................. 14 kg

7-4

SECTION 7 - LUBRICATION/FILTERS/FLUIDS GREASE POINTS Type of grease ..................................................................................................................... See "Fluids and lubricants" To facilitate access to the different grease points, place the attachment in the position shown in the diagram.

CT02E121

3 NOTE: The numbers within brackets mentioned on the right of the description indicate the number of lubrication points.

NOTE: After lubrication, refit the protective and indicating plastic caps to the grease fittings.

MONOBLOC BOOM/DIPPER/BUCKET LUBRICATION

D

B

E C

J

H

F

G

A

CT02E083

4

7-5

SECTION 7 - LUBRICATION/FILTERS/FLUIDS Every 250 hours

A

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

CT02E088

5 Boom cylinder top pin ............................................... (2)

B

CT02E085

6 Dipper cylinder bottom pin........................................ (1)

C

CT02E086

7 Dipper cylinder top pin .............................................. (1)

D

CT02E089

8 7-6

SECTION 7 - LUBRICATION/FILTERS/FLUIDS Bucket cylinder bottom pin ....................................... (1)

E

CT02E094

9 IMPORTANT: If an accessory other than the bucket is installed (hydraulic hammer, etc.), these linkage points must be lubricated every 10 hours.

Bucket cylinder top.................................................... (1)

F

CT02E090

10 Dipper/bucket linkage ............................................... (5)

G

CT02E091

11

7-7

SECTION 7 - LUBRICATION/FILTERS/FLUIDS

G

CT02E092

12 IMPORTANT: If the following linkage points are not equipped with original parts, these points must be lubricated every 50 hours.

Every 1000 hours Boom bottom pin....................................................... (3)

H

CT02E084

13 Boom/dipper linkage................................................. (2)

F

CT02E093

14

7-8

SECTION 7 - LUBRICATION/FILTERS/FLUIDS QUICK COUPLER TOOL LUBRICATION (optional) Every 50 hours Cylinder bottom......................................................... (1) Locking system pivot ................................................ (1)

CT02D344

15 Cylinder top............................................................... (1)

CT02D345

16 Hook pivot ................................................................. (1)

CT02D346

17

7-9

SECTION 7 - LUBRICATION/FILTERS/FLUIDS MACHINE LUBRICATION Every 500 hours Turntable bearing ...................................................... (2)

CT02C245

18 Every 2000 hours Swing reduction gear................................................ (1) See "Greasing the swing reduction gear".

CT02E105A

19 Every 50 hours Dozer blade (if equipped) ......................................... (2) Dozer blade cylinder (if equipped)............................ (4)

CT02C263

20

7-10

SECTION 7 - LUBRICATION/FILTERS/FLUIDS GREASING THE TURNTABLE TEETH Grease capacity...................................................................................................................................................... 14 kg Type of grease ..................................................................................................................... See "Fluids and lubricants" Every 500 hours Remove the panel (1), the 2 screws (2) and the seal (3), check for damage on the gear teeth and their condition.

If the gear surface is not well greased, add grease.

2

If the grease is white due to moisture content, etc. replace it with new grease.

If water accumulation is found:

3

- Remove the protective panel from the lower central area.

1

- Remove the plug.

CT02E095

- Discharge the water or contaminated grease.

21

- Install the plug.

- Insert new grease through the port, then install the panel (1).

GREASING THE SWING REDUCTION GEAR Grease capacity..................................................................................................................................................... 0.6 kg Type of grease ..................................................................................................................... See "Fluids and lubricants" Every 2000 hours Remove the lower panel, remove the air bleed plug (1) and refill with grease through the grease point (2). A certain amount of grease should run out from the air bleed plug (1).

IMPORTANT: When greasing, if the air bleed plug (1) is not removed, the inner seal will be damaged.

1

2 CT07M029

22

7-11

SECTION 7 - LUBRICATION/FILTERS/FLUIDS LEVELS Type of fluids and lubricants.............................................................................................. See "Fluids and lubricants" Every 10 hours NOTE: The numbers within brackets mentioned on the right of the description indicate the number of levels.

Coolant solution expansion reservoir....................... (1)

CT02E098 CT02C288

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

CT02E099

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

CT02E100

25

7-12

SECTION 7 - LUBRICATION/FILTERS/FLUIDS Every 250 hours Batteries.................................................................... (2)

CT02E101

26 Travel reduction gears .............................................. (2)

CT02E102

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

CT02E103

28

7-13

SECTION 7 - LUBRICATION/FILTERS/FLUIDS ENGINE SERVICE SPECIFICATIONS Engine oil level check......................................................................................................... Every 10 hours or every day Oil change ............................................................................................................................................. Every 500 hours Oil filter replacement............................................................................................................................. Every 500 hours Oil type ................................................................................................................................. See "Fluids and lubricants" Oil capacity....................................................................................................................................................... 23.1 litres LEVEL 1.

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

2.

hen the engine has been stopped for fifteen minutes, remove the dipstick (1), wipe it with a clean cloth and replace it in the guide tube as far as it will go. Then take it out again.

1

CT07M011

29 3.

If the level is situated between the marks (A) and (B) on the dipstick, the level is correct.

B

A

CS98M579

30 4.

If the oil level is at mark (A) (min) or below, remove the filling cap and add oil up to mark (B) (max) of the dipstick then install the cap.

NOTE: The level should not be higher than the mark (B) (maximum on the dipstick).

CT07M011A

31 7-14

SECTION 7 - LUBRICATION/FILTERS/FLUIDS DRAINING, REPLACING THE OIL FILTER AND FILLING NOTE: Change the oil while the engine is still warm.

The oil will flow more easily.

Use the extension drain hose from the storage compartment.

1.

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

2.

Remove the oil filler cap (1).

1

CT07M011A

32 3.

Remove the protective cap from the engine housing drain valve.

4.

Screw the end of the extension drain hose onto the engine housing drain valve (2), place the other end in a container of suitable capacity and allow the oil to flow out.

5.

Remove the extension drain hose and install the protective cap on the engine housing drain valve.

Place the extension drain hose in the storage compartment.

2

CT07M012

33 6.

Clean the area around the oil filter (3) and remove it, using a filter wrench.

3 CT07M011

34

7-15

SECTION 7 - LUBRICATION/FILTERS/FLUIDS 7.

Coat the seal of the new filter with a fine film of oil.

8.

Install the new filter. Turn the filter until the seal comes into contact with the filter head then tighten an extra half turn by hand.

IMPORTANT: Do not use a filter wrench to tighten the filter. Excessive tightening can damage the filter and the seal.

9.

Fill the engine with new engine oil (23.1 litres).

Install the filling cap.

10. Run the engine for a few minutes and check that there are no leaks. Check the level again and top up if necessary.

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

7-16

CT02D301

35

SECTION 7 - LUBRICATION/FILTERS/FLUIDS COOLING SYSTEM SERVICE SPECIFICATIONS Expansion reservoir level check........................................................................................ Every 10 hours or every day Checking the tightening of clamps, of radiator hoses............................................Every 250 hours or every 6 months Draining the system (long duration) ........................................................................Every 1000 hours or every 2 years Draining the system (with anti-freeze) (spring and autumn) ......................................................................Twice a year System capacity................................................................................................................................................25.6 litres

!

WARNING

!

Boiling coolant solution can spray out if the radiator cap is removed while the system is still hot. To remove the cap, allow the system to cool down, turn the cap to the first notch and wait until there is no more pressure. Then remove the cap.

!

WARNING

!

WARNING

!

Coolant solution is toxic.

Avoid contact with skin, eyes and clothing.

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

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

EYES: rinse thoroughly with water and seek medical advice.

!

Check and service the cooling system according to the instructions given in this manual.

COOLANT SOLUTION Put only ethylene-glycol coolant solution in the cooling system. Use good quality ethylene-glycol that has a high boiling point, with no additives to prevent leakage.

Do not use non-approved anti-rust additives. Anti-rust additives and ethylene-glycol can mix and work against each other, thereby reducing anti-corrosion protection, forming deposits in the cooling system and causing damage to the cooling system and radiator.

Consult your CASE Dealer for suitable coolant solution.

7-17

SECTION 7 - LUBRICATION/FILTERS/FLUIDS To access the expansion reservoir, lower completely the swing reduction gear hood located at the front of the machine.

CT02E096

36 LEVEL

1

The level of coolant solution should be checked when the engine is cold.

On flat, level ground, before using the machine, (while the engine is still cold), the level in the expansion reservoir should be between the "Full" (1) and "Low" (2) marks. If not, see "Filling".

2

CT02E110

37 DRAINING 1.

Remove the radiator cap.

!

WARNING

!

Do not remove the radiator cap when the engine is hot. The system is still under pressure and you could be scalded.

CT02E111

38 2.

Remove the panel located under the upperstructure and open the radiator drain valve.

CT02E112

39 7-18

SECTION 7 - LUBRICATION/FILTERS/FLUIDS 3.

Open the drain plug located on the engine block.

NOTE: Have a receptacle of a suitable capacity ready.

CT02E113

40 RINSING 1.

Close the drain valve when the radiator is completely empty. Install the plug on the engine block.

2.

Fill the system with clean water. Install the radiator cap.

3.

Start the engine. Run the engine at a speed slightly higher than idle speed for ten minutes to bring the engine temperature up to about 80°C.

4.

Stop the engine and remove the starter switch key.

5.

Drain the system once more.

6.

Repeat Steps 1 to 5 until the water drained is clear.

7.

Install the panel under the upperstructure.

7-19

SECTION 7 - LUBRICATION/FILTERS/FLUIDS FILLING 1.

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

CT02E111

41 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.

4.

Close the hood.

CT02E110

42

7-20

SECTION 7 - LUBRICATION/FILTERS/FLUIDS FUEL SYSTEM SERVICE SPECIFICATIONS Fuel tank bleeding ............................................................................................................. Every 10 hours or every day Pre-filter bleeding...................................................................................................When the float reaches the level (A) Filter bleeding.........................................................................................................When the float reaches the level (A) Change the pre-filter element............................................................................................................... Every 250 hours Change the filter element ..................................................................................................................... Every 500 hours Fuel supply pump filter cleaning....................................................................................................................Periodically Fuel tank capacity..............................................................................................................................................265 litres Type of fuel........................................................................................................................... See "Fluids and lubricants"

!

WARNING

!

Take all necessary precautions during the following operations; no foreign matter must enter the fuel system.

!

WARNING

!

Completely wipe off any spilt fuel after changing a filter element or bleeding the system.

DRAINING THE FUEL TANK 1.

Position a drain pan under the drain plug.

2.

Open the drain valve located at the bottom of the tank and drain the accumulated sediment and water.

3.

After draining, close the drain valve.

CT02E115

43

7-21

SECTION 7 - LUBRICATION/FILTERS/FLUIDS PRE-FILTER BLEEDING When the float reaches the level (A) (base of the filter element): 1.

Place a receptacle of a suitable capacity under the pre-filter located at the rear of the fuel tank.

2.

Loosen the drain plug (1) and the bleed screw (2) then drain the water and sediment.

3.

When the float (3) settles on the bottom, tighten the drain plug (1) to a torque of between 8 and 12 Nm, then tighten the bleed screw (2).

2

A

IMPORTANT: Overtightening can damage the seal.

4.

1

Check for any signs of leak.

NOTE: In cold weather, the water can freeze on the top part of the bowl. Bleed after the ice has melted.

3 CT07M015

44 CHANGING THE PRE-FILTER ELEMENT

!

WARNING

!

If a fuel filter other than a genuine CASE filter is used, the guarantee will not be applied to a fault caused by the use of a wrong filter.

1.

Place a receptacle of a suitable capacity under the pre-filter.

2.

Close the valve on the supply line.

CT07M030

45

7-22

SECTION 7 - LUBRICATION/FILTERS/FLUIDS 3.

Loosen the drain plug (1) and the bleed screw (2) then let the pre-filter drain.

4.

Clean around the pre-filter body (3) then remove it using the wrench provided with the machine.

5.

Install the new filter element (4). Replace the filter body seal, then install the body (3), turning it until it is in contact with the pre-filter head.

2

6.

Tighten the body using the wrench, the tightening torque must be from 27.5 to 31.3 Nm.

7.

Replace the drain plug (1) seal then install the drain plug (1); the tightening torque must be between 8 and 12 Nm.

3

4

IMPORTANT: Do not fill the filter body with fuel before installing.

1 CT07M015

46

IMPORTANT: Overtightening can damage the seals.

IMPORTANT: Never re-use the seals of the filter body (3) or the drain plug (1); they must always be replaced with new seals.

8.

Open the valve on the supply line.

9.

Bleed the system. See "Fuel system air bleed".

10. Check for any signs of leak.

BLEED THE FILTER Proceed in the same manner as for the pre-filter. See "Pre-filter bleeding".

CT07M030

47

7-23

SECTION 7 - LUBRICATION/FILTERS/FLUIDS CHANGING THE FILTER ELEMENT

!

WARNING

!

If a fuel filter other than a genuine CASE filter is used, the guarantee will not be applied to a fault caused by the use of a wrong filter.

Proceed in the same manner as for the pre-filter. See "Changing the pre-filter element".

CT07XXX

48 FUEL SYSTEM AIR BLEED It is necessary to bleed the fuel system when: -

The tank has been completely emptied.

The fuel pre-filter has been changed.

The fuel filter has been changed.

Parts of the fuel system have been removed for servicing or repair work.

- The machine has been in storage for a fairly long period.

1.

Loosen the air bleed screw (1).

2.

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

3.

Turn the priming pump piston (2) to the left in order to release the spring.

4.

Move the handle of the priming pump (2) up and down until fuel containing no air bubbles flows out of the air bleed screw (1).

5.

As soon as fuel containing no air bubbles flows out, tighten the air bleed screw (1) and tighten the priming pump piston (2).

6.

Completely wipe off any spilt fuel. Start the engine and check for possible leakage.

!

WARNING

!

Completely wipe off any spilt fuel. It could cause a fire.

7-24

2

1

CT07M031

49

SECTION 7 - LUBRICATION/FILTERS/FLUIDS CLEANING THE FUEL SUPPLY PUMP FILTER 1.

Place a receptacle of suitable capacity under the supply pump (1) located near the fuel pre-filter.

2.

Close the valve on the supply line (2) then remove the supply pump.

1

2 CT07M030

50 3.

Open the pump body and extract the filter (2) and the seals (1) and (3).

IMPORTANT: Always protect your face before using compressed air.

4.

2 4

Clean the filter with compressed air. Check the filter and replace it if necessary. Replace the seals with new seals.

5.

Carefully clean the body (4) and the cover (5). No dirt must remain in the supply pump.

6.

Re-assemble, taking care to install the seals in the correct order then re-install the pump.

7.

Open the valve on the supply line.

8.

Bleed the system. See "Fuel system air bleed".

5 1 3 CT07B007

51

7-25

SECTION 7 - LUBRICATION/FILTERS/FLUIDS FILLING THE FUEL TANK The tank cap is located on the RH underside of the machine.

1.

Clean carefully around the filling cap. Remove the cap using the starter switch key.

2.

Fill the tank, make sure that no water or dust enters the tank.

IMPORTANT: Never remove the tank filter for filling.

!

WARNING

!

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

IMPORTANT: In cold weather, use fuel corresponding to the ambient temperature. See "Fluids and lubricants". Fill the fuel tank after each working day to prevent the formation of condensation.

3.

Install the filler cap, lock it using the starter switch key.

IMPORTANT: Make sure that the cap is correctly locked.

7-26

CT02E071

52

SECTION 7 - LUBRICATION/FILTERS/FLUIDS RELEASING PRESSURE IN THE HYDRAULIC SYSTEM IMPORTANT: Before carrying out any work on the hydraulic system, there should be no pressure in any of the circuits.

1.

Place the machine on flat, level ground, lower the attachment to the ground and stop the engine.

2.

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

CT02D268

53 3.

Lower the control locking lever.

CT02E074

54 4.

Operate the control levers from right to left and front to rear a dozen times approximately.

CT02E077

55

7-27

SECTION 7 - LUBRICATION/FILTERS/FLUIDS 5.

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

CT02C195

56 6.

Press the button (1) located above the breather to release any possible pressure.

1

CT02E120

57

!

WARNING

!

Stop the engine, press the pressure release button and completely bleed air from the reservoir.

!

WARNING

!

Make sure that you don’t get scalded with the hydraulic fluid under high pressure. The temperature should not exceed 40°C.

7-28

SECTION 7 - LUBRICATION/FILTERS/FLUIDS HYDRAULIC SYSTEM SERVICE SPECIFICATIONS Check the hydraulic reservoir fluid level............................................................................. Every 10 hours or each day Check the lines ....................................................................................................................................... Every 50 hours Draining water and sediment from the hydraulic reservoir.................................................................. Every 250 hours Check the condition of the hydraulic fluid........................................................................................... Every 1000 hours Change the reservoir breather filter element ..................................................................................... Every 1000 hours Clean the inlet filter ............................................................................................................................. Every 2000 hours Change the return filter....................................................................................................................... Every 2000 hours (after the first 250 hours during the run-in period) Change the pilot filter.......................................................................................................................... Every 2000 hours (after the first 250 hours during the run-in period) Change the main pump outlet hoses......................................................................Every 2 years or every 4000 hours (whichever comes first) Change the boom, dipper and bucket cylinder hoses ............................................Every 2 years or every 4000 hours Replace the inlet filter ......................................................................................................................... Every 5000 hours Change the hydraulic fluid.................................................................................................................. Every 5000 hours Reservoir capacity .............................................................................................................................................120 litres Total system capacity ........................................................................................................................................205 litres Oil type ................................................................................................................................. See "Fluids and lubricants" IMPORTANT: If biodegradable fluid is used, it is essential to reduce the following servicing intervals to the number of hours shown: Replace the return filter ...................................................................................................................... Every 1000 hours (after the first 50 hours during the run-in period) Change the hydraulic fluid.................................................................................................................. Every 2000 hours NOTE: If the machine is new or if a major component has been overhauled or 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 analysed. Consult 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".

IMPORTANT: If metal particles are discovered in the replaced filters, consult your CASE Dealer.

!

WARNING

!

Before carrying out any service work on the hydraulic system it is necessary to allow it to cool down (the temperature should not be more than 40°C).

!

WARNING

!

Hydraulic fluid or grease injected into your skin can cause severe injury or death. Keep your hands and body away from any pressurized leak.

Use cardboard or paper to check for a leak. If fluid is injected into your skin, see a doctor immediately and have the fluid removed.

!

WARNING

!

Before carrying out any operation on the hydraulic filters or the hydraulic system, the pressure must be released from the system. Failure to observe this instruction can cause injury. See "Releasing pressure in the hydraulic system".

7-29

SECTION 7 - LUBRICATION/FILTERS/FLUIDS LEVEL IN THE RESERVOIR 1.

Park the machine on flat, horizontal ground.

Extend completely the bucket and dipper cylinder rod. Raise the dozer blade (if equipped). Lower the attachment to the ground. Shut down the engine and remove the starter switch key.

CT02E121

58 2.

Using the starter switch key, open the RH side door.

3.

The oil must be located in the middle of the indicator. Top up if necessary. See "Filling the hydraulic reservoir".

CT02E100

59

7-30

SECTION 7 - LUBRICATION/FILTERS/FLUIDS ACCESSING THE HYDRAULIC RESERVOIR 1.

Open the hood (1) and lock it with the lever (2).

2 1

CT02E122

60 2.

Remove the screws (4) and the chamber (3) (if equipped): (If equipped) disconnect the fuel filler pump.

4

3

CT02E123

61

CT02E125

62

7-31

SECTION 7 - LUBRICATION/FILTERS/FLUIDS FILLING THE HYDRAULIC RESERVOIR To access the hydraulic reservoir, see "Accessing the hydraulic reservoir".

1.

Release all pressure in the hydraulic reservoir.

See "Releasing pressure in the hydraulic system".

2.

Clean the plate and also around the plate.

Remove the 4 screws (1) and the plate (2) then add hydraulic fluid as required.

!

WARNING

!

Make sure that no contaminant (water, sand etc.) enters the reservoir during filling.

1 2

CT02E125

63 3.

Check the max and min level by monitoring the dipstick.

Install the plate (2) and the 4 screws (1). Replace the cover seal if required.

CT02E100

64 PILOT FILTER REPLACEMENT To access the filter, open the rear RH side door.

Release the pressure in the hydraulic system. See "Releasing pressure in the hydraulic system".

Unscrew and remove the filter using a wrench.

Coat the seal of the new filter with a fine film of clean oil.

Install the new filter. Turn the filter until the seal comes into contact with the filter head then tighten by an extra third of a turn by hand.

CT02E126

65

7-32

SECTION 7 - LUBRICATION/FILTERS/FLUIDS CLEANING AND REPLACEMENT OF THE INLET FILTER To access the hydraulic reservoir, see "Accessing the hydraulic reservoir".

1.

Release all pressure in the hydraulic reservoir.

See "Releasing pressure in the hydraulic system".

2.

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

CT02E125

66 3.

4.

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

1

Remove the inlet filter (4) and clean with solvent.

Dry it completely and check it for any damage. If there is any damage on the surface, replace it with a new one.

5.

Install a new O-ring (2) and install the inlet filter (4), spring (3) and rod assembly.

6.

Install the cover (1).

7.

Check the level of the hydraulic fluid and add more if necessary. See "Filling the hydraulic reservoir".

2 3

NOTE: Install a new inlet filter every 5000 hours of operation or when the hydraulic fluid is replaced.

4

CT07M032

67

7-33

SECTION 7 - LUBRICATION/FILTERS/FLUIDS RETURN FILTER REPLACEMENT To access the hydraulic reservoir, see "Accessing the hydraulic reservoir".

1.

Release all pressure in the hydraulic reservoir.

See "Releasing pressure in the hydraulic system".

2.

To access the filter, remove the screws (1) and the plate (2).

2

1 CT02E127

68 3.

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

4.

Remove the 4 screws (3) and the cover (4).

3

4 CT02E128

69 5.

Take out the O-ring (5), spring (6), valve (7) and filter (8).

6.

Install a new filter. Clean the spring (6) and valve (7) and install them.

7.

Check O-ring (5) and replace it if worn or damaged.

6

8.

Install the cover (4).

7

9.

Check the level of the hydraulic fluid and add more if necessary. See "Filling the hydraulic reservoir".

4 5

8 CT07M033

70

7-34

SECTION 7 - LUBRICATION/FILTERS/FLUIDS REPLACING THE RESERVOIR BREATHER FILTER ELEMENT To access the hydraulic reservoir, see "Accessing the hydraulic reservoir".

CT02E130

71 1.

Press the button (1) to release all pressure in the hydraulic reservoir.

2.

Remove the nut (2) and the cover (3) from the breather.

3.

Remove and discard the used filter (4).

4.

Install a new element (4), making sure the seal (5) is facing upwards.

5.

Install the cover (3) as well as the nut (2).

1 2 3 5

4

CS00E528

72

7-35

SECTION 7 - LUBRICATION/FILTERS/FLUIDS REPLACING THE HYDRAULIC FLUID To access the hydraulic reservoir, see "Accessing the hydraulic reservoir".

1.

Release all pressure in the hydraulic reservoir.

See "Releasing pressure in the hydraulic system".

2.

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

3.

Remove the screws (1) and the tank filling cover (2).

1

2

CT02E125

73 4.

Place a container of a suitable capacity under the tank drain plug, remove the drain plug from the tank (3) and let the remaining fluid escape.

3

CT02E131A

74 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 (3).

7.

Put new hydraulic fluid into the reservoir. See "Filling the hydraulic reservoir".

8.

Install the reservoir cover plate and seal.

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".

7-36

SECTION 7 - LUBRICATION/FILTERS/FLUIDS 9.

Start and run the engine with no load for approximately five minutes.

10. Move each control several times to remove any air in the system.

11. Swing the upperstructure evenly left to right two complete turns or more.

12. Place the machine in position and then stop the engine.

13. Check the oil level in the hydraulic reservoir and add oil as required and check that there are no air bubbles in the hydraulic reservoir.

14. Bleed the components, see "Bleeding the hydraulic components".

BLEEDING AIR FROM THE HYDRAULIC COMPONENTS IMPORTANT: After bleeding air from the components, stop the engine for five minutes and check there are no bubbles at the surface of the hydraulic fluid in the reservoir.

Hydraulic pump Using a solvent, clean around the air bleed plug.

Loosen the air bleed plug (1), remove the plug if the fluid does not flow.

Fill the pump with hydraulic fluid via port (1). Install and tighten the air bleed plug.

1

Start the engine and run it at low speed. Loosen the air bleed plug (1) on the pump. Tighten the plug when air free fluid comes out of the bleed plug hole. Clean the area completely.

CT02E132

75

7-37

SECTION 7 - LUBRICATION/FILTERS/FLUIDS Attachment cylinders Start and run the engine at low idle speed. Extend and retract the attachment cylinder rods four or five times without bringing them to end of stroke. Then repeat the operation three or four times, this time bringing the cylinder rods to end of stroke.

Swing reduction gear Start and run the engine at low idle speed. Loosen the air bleed plug (1) and make sure hydraulic fluid runs out through this port. If required, shut down the engine and top up via port (1). Install the plug without tightening, then start and run the engine at low idle, leaving it to run until oil begins to run from the orifice. Tighten the air bleed plug (1) completely. Swing the upperstructure three times completely to the right and three times completely to the left.

1

After complete bleeding, stop the engine for five minutes then check that there are no air bubbles in the hydraulic reservoir.

CT02E133

76

7-38

SECTION 7 - LUBRICATION/FILTERS/FLUIDS REPLACING THE HYDRAULIC FILTERS AND FLUID WHEN A HYDRAULIC BREAKER IS USED (optional) Hydraulic fluid - When using the hydraulic breaker, hydraulic fluid deteriorates more quickly than during ordinary digging. Check the hydraulic fluid level more frequently.

In addition, when replacing the filters, also check the condition of the hydraulic fluid.

- Using the following table as a reference, determine the intervals for changing the hydraulic fluid and filters, depending on the frequency of use of the hydraulic breaker.

Percentage of use Interval in hours

100% 10

100

40% 600

10

300

20% 1500

10

600

10% 3000

10

800

Page

Service points

7-29

Hydraulic fluid

7-29

Return circuit filter

(3)

7-29

Inlet filter

(2)

7-29

Pilot filter

(3)

(3)

(3)

(3)

7-29

Hydraulic fluid condition

200 h

300 h

600 h

800 h

(1)

(3)

(1)

(3) (3)

(3)

(1) Check the level (2) Clean or replace

(2)

(1)

(3) (3)

(3)

(2)

(1)

4000

(3) (3)

(3)

(2)

(3)

(3) Replace

CHECKING THE HYDRAULIC SYSTEM PIPING Make sure there are no leaks from the hydraulic system hoses, pipes, plugs, connections and fittings and check that all nuts and screws are correctly tightened.

In the event of problems, repair, replace or tighten the component(s) concerned.

7-39

SECTION 7 - LUBRICATION/FILTERS/FLUIDS AIR FILTER To access the air filter, open the LH side door and install the supporting strut.

CT02F001

77 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.

AIR FILTER RESTRICTION INDICATOR Located below the air filter, this indicator (1) 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.

1 CT02F002

78

7-40

SECTION 7 - LUBRICATION/FILTERS/FLUIDS SERVICE SPECIFICATIONS Inspect and clean the primary element................................................................................................ Every 250 hours or when central zone of the indicator turns red Replace the primary element............................................................................................................. Every 1000 hours or after cleaning six times Replace the secondary element ........................................................................................................ Every 1000 hours IMPORTANT: The primary element can be cleaned.

The secondary element can not be cleaned and must be replaced.

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

REMOVING THE ELEMENTS 1.

Release the fasteners and remove the cover.

CT02F003

79 2.

Remove the primary element.

CT02F004

80

7-41

SECTION 7 - LUBRICATION/FILTERS/FLUIDS 3.

Remove the secondary element if it needs replacing.

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

CT02F005

81

7-42

SECTION 7 - LUBRICATION/FILTERS/FLUIDS CLEANING THE PRIMARY ELEMENT IMPORTANT: Always protect your face before using compressed air.

If the primary element is dry: Blow compressed air from the inside towards the outside at very low pressure. The compressed air nozzle should be held at least 3 cm from the inside wall of the element. Cleaning is completed once no more dust comes out of the primary element.

IMPORTANT: Compressed air pressure should not exceed 7 bar.

CT02D120

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

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

IMPORTANT: Allow the element to dry completely before installing it. It is advisable to keep a spare, clean element ready for installation on the air filter while the cleaned element is drying.

PDE0088

83 INSPECTING THE ELEMENT Check the element for damage by placing an inspection lamp inside the element.

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

PDE0378A

84

7-43

SECTION 7 - LUBRICATION/FILTERS/FLUIDS CLEANING THE ELEMENT HOUSING Remove dust from the housing of the elements and its cover.

CT02D393

85 INSTALLING THE ELEMENTS 1.

Install the secondary element.

CT02F005

86 2.

Install the primary element.

CT02F004

87

7-44

SECTION 7 - LUBRICATION/FILTERS/FLUIDS 3.

Install the cover (with the word "TOP" at the top) and close the fasteners.

CT02F003

88 4.

Check that the dust ejector (1) under the filter is working correctly.

5.

Press the red button on the indicator (2).

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

2

1

CT02F002

89

7-45

SECTION 7 - LUBRICATION/FILTERS/FLUIDS SWING REDUCTION GEAR SERVICE SPECIFICATIONS Oil level check ....................................................................................................................................... Every 250 hours Oil change ........................................................................................................................................... Every 1000 hours (after the first 250 hours during the run-in period) Grease (see "Greasing the swing reduction gear" ............................................................................ Every 2000 hours Oil capacity............................................................................................................................................................ 5 litres Oil type ................................................................................................................................. See "Fluids and lubricants"

!

WARNING

!

Wait till all components have cooled down before carrying out any operation.

!

WARNING

!

Loosen the dipstick slowly to release pressure, otherwise there is a risk of oil spurting out.

1.

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

2.

To access the swing reduction gear, completely tilt the swing reduction gear hood located at the front of the machine.

CT02E096

90 LEVEL 1.

Remove the dipstick. The level should come up to the hatched area.

CT02E103

91

7-46

SECTION 7 - LUBRICATION/FILTERS/FLUIDS 2.

If necessary, top up through the filler port.

3.

Install the dipstick.

CT02F006

92 DRAINING AND REFILLING 1.

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

2.

Remove the dipstick (1) and the filling cap (2).

1 2 CT02E103

93 3.

Place a receptacle of a suitable capacity under the upperstructure and remove the drain plug (3).

4.

Allow the oil to drain.

3

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

IMPORTANT: Check the condition of the drained oil. If it contains metal filings or foreign matter, consult your CASE Dealer.

5.

Install the drain plug (3).

CT02F007

94

7-47

SECTION 7 - LUBRICATION/FILTERS/FLUIDS 6.

Add oil through the filler port (2) until the level is correct.

7.

Install the dipstick (1) and the filling cap (2).

8.

Wait ten minutes and then use the dipstick to check the level again. If necessary, top up through the filler port (2).

NOTE: When greasing the swing reduction gear, see "Greasing the swing reduction gear".

1 2 CT02E103

95

7-48

SECTION 7 - LUBRICATION/FILTERS/FLUIDS TRAVEL REDUCTION GEARS SERVICE SPECIFICATIONS Oil level check ....................................................................................................................................... Every 250 hours Oil change........................................................................................................................................... Every 1000 hours (after the first 250 hours of operation) Oil capacity (per reduction gear .........................................................................................................................4.7 litres Oil type ................................................................................................................................. See "Fluids and lubricants" LEVEL 1.

Park the machine on flat, horizontal ground.

2.

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

3.

Stop the engine and remove the starter switch key.

4.

Slowly loosen the plug (3) to release any residual pressure.

5.

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

3 2

1 CT02F010

6.

If necessary, replace the seals of plugs (2) and (3) then replace the plugs.

7.

Repeat Steps 2 to 6 for the other travel reduction gear.

8.

Travel slowly with the machine and make sure there are no leaks.

96

7-49

SECTION 7 - LUBRICATION/FILTERS/FLUIDS DRAINING AND REFILLING 1.

Park the machine on flat, horizontal ground.

2.

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

3.

Shut down the engine and remove the starter switch key.

4.

Place a receptacle of a suitable capacity under the travel reduction gear.

5.

Slowly loosen the plug (3) to release any residual pressure then remove the three plugs (1), (2) and (3).

6.

Allow the oil to drain.

IMPORTANT: Check the condition of the drained oil. If it contains metal filings or foreign matter, consult your CASE Dealer.

7.

If required, replace the plug seals.

8.

Install the plug (1), fill with oil through the port (3) until oil comes up to the bottom edge of port (2), then install the plugs (2) and (3).

9.

Repeat Steps 2 to 8 for the other travel reduction gear.

10. Travel slowly with the machine and make sure there are no leaks.

7-50

3 2

1 CT02F010

97

SECTION 8

37

MAINTENANCE/ADJUSTMENTS TRACKS MAINTENANCE SPECIFICATIONS Clean............................................................................. Periodically and when the machine has been working in mud Check tension ................................................................................................................................................Periodically Check steel pad screw torques ............................................................................................................ Every 250 hours (after the first 50 hours during the run-in period) IMPORTANT: If the tracks are too tight, they wear quickly. If tracks are not tight enough, they wear quickly and the links can catch on the sprocket wheel or slide off the idler wheel or the sprocket wheel. Clean the tracks after work.

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

1.

Place the upperstructure at right angles to the undercarriage. Use the attachment to press on the ground and lower the boom until the track is raised off the ground. Then place a block beneath the undercarriage to relieve the attachment.

!

WARNING

!

Only raise the track as little as necessary. Raising it too much can cause the machine to tip over.

NOTE: For machines fitted with the dozer blade, the machine can be lifted by completely lowering the blade and by using the attachment as a support on the ground, opposite the blade.

2.

CT02F011

1

Put the engine throttle button (1) on the maximum speed position and select the fast speed (2).

2 1

CT02D156

2

8-1

SECTION 8 - MAINTENANCE/ADJUSTMENTS 3.

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

4.

With the track raised, check the track tension.

5.

Repeat Steps 1 to 4 for the other track.

CT02E044

3 CHECKING THE TENSION 1.

If the track is not yet raised, put the machine into the required position by proceeding in the same manner as for cleaning. See "Cleaning".

2.

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

3.

Stop the engine and remove the starter switch key.

CT02E044

4 4.

Measure the slack between the base of the undercarriage and the upper part of the track tread. See "Track tension value".

5.

Adjust the tension if necessary and then lower the raised track to the ground.

6.

Repeat Steps 1 to 5 for the other track.

CT02F012

5

8-2

SECTION 8 - MAINTENANCE/ADJUSTMENTS ADJUSTING THE TENSION NOTE: This operation is to be carried out after the tension has been checked.

To increase tension 1.

Clean the grease fitting adaptor and the grease fitting.

2.

Connect the grease pump. Inject grease to obtain the right amount of track sag. See "Track tension value".

3.

Remove the grease pump and clean the grease fitting.

4.

Repeat Steps 1 to 3 for the other track.

CT02D177

6 To reduce tension 1.

Slowly loosen the grease fitting adaptor by about three turns to allow grease to flow out of the cylinder.

!

WARNING

!

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

2.

As soon as the right track sag is obtained, tighten the adaptor. See "Track tension value".

3.

Clean the grease adaptor and fitting and then lower the raised track to the ground.

4.

Repeat Steps 1 to 3 for the other track.

CT02D178

7

IMPORTANT: If the grease fitting adaptor is damaged, grease may leak out. Check the condition of the grease fitting adaptor regularly and replace it if necessary.

8-3

SECTION 8 - MAINTENANCE/ADJUSTMENTS TRACK TENSION VALUE The value should be between: Steel tracks: 280 - 300 mm Rubber tracks and steel chains: 260 - 280 mm TIGHTENING TORQUE OF THE TRACK PAD SCREWS IMPORTANT: Regularly check the tightening of the screws. Do not use the machine with the track pad screws loose, the screws may come off and damage the track.

The tightening torque of the screws should be between: 300 Nm + 120° ± 5° IMPORTANT: Follow the prescribed order.

1

3

4

2

CS00E504

8

TRACK ROLLERS AND IDLER WHEELS MAINTENANCE SPECIFICATION Check .................................................................................................................................................... Every 250 hours The upper (1) and lower rollers (2) and idler wheels (3) use a permanent floating seal type sealing mechanism. The service life normally lasts until overhaul, but check visually from time to time before work for oil leakage. If oil leakage is found, component replacement is necessary. Consult your CASE Dealer.

3

1

2 CT02F013

9

8-4

SECTION 8 - MAINTENANCE/ADJUSTMENTS RADIATOR AND OIL COOLER MAINTENANCE SPECIFICATIONS Check for leakage.............................................................................................................. Every 10 hours or every day Clean..................................................................................................................................................... Every 500 hours CLEANING 1.

Shut down the engine, remove the starter switch key and open the engine hood.

2.

Open the rear LH side door and block it with the supporting strut.

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

CT02F017

10 3.

Loosen the four wing nuts (1) and remove the two protective grilles (2) to access the radiator.

4.

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

- Mud: use a water jet.

- Greasy dust: use perchlorethylene.

1

IMPORTANT: The use of trichlorethylene is strictly forbidden.

5.

2

Install the grilles (2) and the wing nuts (1) then close the engine hood and the rear LH side door.

!

WARNING

!

CT02F016

11

Before any travel operation make sure that the locking of the engine hood and rear LH side door is correct.

8-5

SECTION 8 - MAINTENANCE/ADJUSTMENTS FAN AND ALTERNATOR DRIVE BELT MAINTENANCE SPECIFICATIONS Visual check ....................................................................................................................... Every 10 hours or every day Checking the tension of the belts ......................................................................................................... Every 250 hours CHECKING THE TENSION IMPORTANT: If the engine runs with the belts slack, the belts can slip in their housing and cause the engine to overheat or the battery to receive insufficient charge.

With engine shut down and the starter switch key removed, use your finger to exert a pressure of about 10 kg at the centre of the belt. The tension slack should be between about 10 and 15 mm.

NOTE: Check if there are any signs of wear damage to the pulleys or the belts. Check carefully to ensure that the belts are correctly positioned in the pulley grooves. If the belt is stretched, cracked or frayed, it must be replaced.

CS98M560

12 ADJUSTING THE TENSION Remove the mounting bolts (1). Use the adjustment screws (2) to move the alternator outwards until belt tension is correct. Tighten the alternator mounting bolts (1).

1 2

1 CS99A852

13

8-6

SECTION 8 - MAINTENANCE/ADJUSTMENTS REPLACING THE BELTS If the belts break, the battery load indicator lights up on the instrument panel. Shut down the engine, remove the starter switch key and change the belts.

CT02D204

14 Remove the mounting bolts (1). Use the adjustment screws (2) to push the alternator inwards.

1

Remove belts that are worn.

2

Install two new belts.

Adjust the belts using the screw (2).

Tighten the mounting bolts (1).

Run the engine for about an hour and then check the tension of the belts again.

NOTE: The two belts have to be changed at the same time.

1 CS99A852

15

8-7

SECTION 8 - MAINTENANCE/ADJUSTMENTS FUEL TANK FILTER MAINTENANCE SPECIFICATION Clean filter ......................................................................................................................................................Periodically Remove the filter and clean it in diesel oil.

NOTE: Use suitable fuel to refill the fuel tank, see "Fluids and lubricants" in section 7.

CT02F014

16

ADJUSTING ROCKER ARM CLEARANCE MAINTENANCE SPECIFICATION Check .................................................................................................................................................. Every 1000 hours NOTE: Have it checked by your CASE Dealer.

INSPECTING AND CLEANING THE MACHINE MAINTENANCE SPECIFICATIONS Inspect and clean...........................................................................................................................................Periodically Or whenever oil or grease has been spilt on the machine. Clean off with steam or a high pressure water jet.

Take the opportunity during this operation to make a visual check of all the welded components (in case of appearance of cracks), the attachment linkages and check the teeth and tooth tips for correct retention and for wear. Look for any leaks and check the condition of all pipes and hoses.

CHECKING THE MACHINE SETTINGS MAINTENANCE SPECIFICATION Have this checked by your CASE Dealer.............................................................................................. Every 6 months

8-8

SECTION 8 - MAINTENANCE/ADJUSTMENTS CHECKING FOR CYLINDER LEAKAGE A cylinder rod should be slightly oily. Check that there are no leaks after a period of work, when the whole hydraulic system is at normal operating temperature.

1.

Wipe clean the rod and bearing on the cylinder to be cleaned.

2.

Operate normally for five or ten minutes.

3.

Extend the cylinder rod.

4.

Carry out the leak test.

ROD APPEARANCE Dry Slightly greasy Oily

TEST

CONCLUSION

Slight traces of oil when a piece of paper is wiped over 20 cm of the rod.

Normal

Paper remains stuck to rod when run over rod.

Normal

Paper remains stuck when placed on rod.

Normal

Very oily or weeping

Each time the cylinder rod is extended, a ring of oil can be seen on the rod.

Leakage

Each time the rod retracts, the excess oil drips from the gland.

Consult your CASE Dealer

CAB PROTECTION (F.O.P.S.) (optional) MAINTENANCE SPECIFICATION Check .................................................................................................................................................... Every 250 hours (after the first 50 hours during the run-in period) MAINTENANCE AND CHECKS Check the retaining hardware, if necessary retighten the screws.

Check the absence of cracks, rust or holes in the protective structure and the components that constitute it.

Ageing, bad weather and accidents can cause damage. If you have even the slightest doubt regarding the condition of the structure, consult your CASE Dealer.

If the protective structure has suffered any accident, it is necessary to replace the damaged components of the structure in order to restore the initial protection, consult your CASE Dealer.

CT08K014

17

8-9

SECTION 8 - MAINTENANCE/ADJUSTMENTS TOOTH TIP WEAR LIMITS ON THE BACKHOE BUCKET The degree to which a tooth tip can be worn can be assessed visually.

It is possible to extend the life of a tooth tip which is wearing unevenly, in a non-symmetrical fashion.

Interchange and turn over the tooth tips regularly (only if symmetrical).

NOTE: Do not wait for 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.

"ESCO" type

CD01D128A

18 "SMARTFIT" type

CT10C002

19

8-10

SECTION 8 - MAINTENANCE/ADJUSTMENTS REPLACING A TOOTH TIP ON A BACKHOE BUCKET "ESCO" type REMOVAL 1.

Place the bucket a few centimetres 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 turning it to the right up to the stop and holding it in this position.

3.

Place the locking pin in position and strike it until it is flush with the tooth tip.

CD01D128A

20

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

"SMARTFIT" type REMOVAL 1.

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

2.

Turn the locking stud 90° in the clockwise direction using a hexagonal wrench.

CT10C002

21 3.

Remove the locking pin then remove the worn tooth tip.

INSTALLATION 1.

Clean the mating surface on the adaptor.

2.

Engage a new tooth tip right up to the stop and hold it in position.

3.

Engage the locking pin until it is flush with the tooth tip.

4.

Turn the locking stud 90° in the anti-clockwise direction using a hexagonal wrench.

CT10C003

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

22

8-11

SECTION 8 - MAINTENANCE/ADJUSTMENTS REPLACING A BACKHOE BUCKET REMOVAL 1.

Place the bucket flat on flat, horizontal ground.

Operate the attachment controls so that the dipper/bucket linkage pin is not gripped by the weight of the dipper.

2.

Stop the engine and remove the starter switch key.

3.

Remove the pins hardware.

CT09F004

23 4.

Remove the bucket pins.

5.

Start the engine, disengage the attachment from the bucket and save the linkage seals for re-use.

CT09F005

24

8-12

SECTION 8 - MAINTENANCE/ADJUSTMENTS INSTALLATION 1.

Make sure the bucket is in a stable position.

2.

Start the engine. Bring the dipper into its housing.

Stop the engine and remove the starter switch key.

3.

Install the linkage seals between the dipper and the bucket. Change them if necessary.

4.

Install the dipper/bucket linkage pin and its hardware.

5.

Start the engine. Bring the bucket rod into its housing, stop the engine and remove the starter switch key.

6.

Install the linkage seals between the rod and the bucket. Change them if necessary.

7.

Install the rod/bucket linkage pin and its hardware.

8.

(If equipped) Adjust the dipper/bucket shimming.

See "Shimming the backhoe bucket".

9.

Grease the linkage pins.

CT09F004

25

SHIMMING THE BACKHOE BUCKET (if equipped) This mechanism is used to adjust the play between the dipper and the bucket in order to eliminate the play caused by wear. Check and adjust the play regularly.

ADJUSTING THE PLAY 1.

Place the bucket flat on flat, horizontal ground and stop the engine.

2.

Check the play (J) between the dipper and the bucket lug.

3.

If the play (J) exceeds 2 mm, remove the four screws, the cap (1) and the shims (2).

4.

Use the shims (2) as a thickness gauge and determine the number of shims required to eliminate the play (J).

5.

Install the number of new shims required.

6.

Install the cap (1) and the four screws.

NOTE: By tightening the cap (1) screws, the inner bushing moves towards the dipper and the play is eliminated.

J

2 1 3

CT02F015

26

IMPORTANT: It is recommended to maintain a play of about 1.2 mm. If the play is insufficient, it may cause wear by friction or seizing.

IMPORTANT: The inner bushing is equipped with a stud that prevents the bushing from rotating. The cap (1) is equipped with a port on its inner surface. Make sure that the stud is inserted in that orifice when the cap (1) is installed.

8-13

SECTION 8 - MAINTENANCE/ADJUSTMENTS FIRE EXTINGUISHER (not supplied) It is strongly recommended to have a fire extinguisher and to place it in the rear LH side compartment in the bracket designed for the purpose.

MAINTENANCE SPECIFICATION Every month: Examine the fire extinguisher and make sure it is not damaged.

Every six months: Have an approved specialist empty and refill the powder in the fire extinguisher.

Every year: Have an approved specialist examine the fire extinguisher.

CS98M573

27

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

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

!

WARNING

!

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

8-14

SECTION 8 - MAINTENANCE/ADJUSTMENTS CHECKING THE QUICK COUPLER LATCHING HOOK OPENING (optional) MAINTENANCE SPECIFICATION Check ...................................................................................................................................................... Weekly and each time the quick coupler is installed IMPORTANT: It is imperative to carry out this check once a week and each time the quick coupler is installed.

1.

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

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

CT02E078

28 2.

Operate the bucket control to retract the cylinder rod completely and maintain the hydraulic pressure so the latching hook retracts and comes up against the locking bar.

CT02C242

29

8-15

SECTION 8 - MAINTENANCE/ADJUSTMENTS 3.

Check the opening measurement (S) of the latching hook.

1 2

Measurement (S) should never exceed the following: Locking bar resting on surface Welded version (1) .................................................................. 115.9 mm (2) .................................................................... 78.6 mm (3) .................................................................... 27.4 mm Cast version (1) .................................................................. 123.1 mm (2) .................................................................... 84.8 mm (3) .................................................................... 34.8 mm Otherwise, consult your CASE Dealer.

Make sure the locking bar is not damaged. Check that it functions correctly and is not fouled by foreign matter.

!

WARNING

!

If the measurement (S) exceeds the maximum authorized, do not use the quick coupler and consult your CASE Dealer.

INCORRECT OPERATION OF THE QUICK COUPLER IMPORTANT: Make sure that the attachment is resting on the ground. Shut down the engine, remove the starter switch key before carrying out one of the following checks.

If the quick coupler does not work correctly, check the following items: - That no pin is broken, bent or lost.

- That the cylinder is not damaged or bent.

- That there are no leaks from hydraulic hoses, etc.

If the problem persists after all these checks, consult your CASE Dealer.

!

WARNING

!

There is a risk of serious injury if maintenance or repairs are not carried out correctly. If you do not understand maintenance procedures, consult your CASE Dealer.

Modification of the quick coupler without prior authorization can cause serious injury. Do not carry out any modification without authorization from your CASE Dealer.

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

8-16

3 S CS00J511

30

SECTION 8 - MAINTENANCE/ADJUSTMENTS AIR CONDITIONING (optional) MAINTENANCE SPECIFICATION Clean the intake filter ...................................................................................................................Every 50 hours Clean the air recycling filter .....................................................................................................................Every 50 hours Replace the filters ............................................................................................................................... Every 5000 hours Have checked by a specialist .................................................................................................................Every 6 months The components of the air conditioning system need servicing at regular intervals. Make sure these intervals are respected, in order to ensure the air conditioning functions correctly and with maximum effectiveness. The air conditioning system contains gas which is subject to strict legislation. Any defect in the system must be fixed rapidly.

!

WARNING

!

Never try to service the air conditioning system yourself. For any service work, consult your CASE Dealer.

NOTE: Operate the air conditioning system at least once a week, if only for a short time. See "Heating, ventilation or air-conditioning" in section 4.

INSPECTION In order to ensure the air conditioning functions correctly, inspect the air conditioner using the procedure outlined below before starting work.

CLEANLINESS OF THE CONDENSER If the condenser is dirty it will not dissipate heat properly. Clean the condenser in water.

IMPORTANT: Never use water under pressure to clean the condenser.

CHECKING THE BELT TENSION Use your finger to exert pressure of around 10 kg on the centre of the drive belt. The tension slack should be between about 8 and 10 mm. If necessary, adjust the belt tension.

CHECKING THE LINES Make a visual check of the lines and make sure there are no accumulations of dust, grease, etc.

CT02D230

31

8-17

SECTION 8 - MAINTENANCE/ADJUSTMENTS CLEANING THE AIR INTAKE AND AIR RECYCLING FILTERS 1.

Remove the screws and the cover plate located under the operator’s seat.

CT02F019

32 2.

Take out the filters (1) and (2) then blow them with compressed air. If they are damaged, replace them.

2

IMPORTANT: Always protect your face before using compressed air.

1

CT02D233

33 3.

Put the filters (1) and (2) in their respective housings.

2 1

CT02D232

34

8-18

SECTION 8 - MAINTENANCE/ADJUSTMENTS 4.

Install the plate and the screws.

CT02F019

35 CHECKING THE CHARGE STATE OF THE SYSTEM 1.

Turn on the air conditioning system, increase engine speed slightly (1400 to 1600 rpm) and look for bubbles through the sight glass.

CT02F020

36 2.

This check should be made approximately one minute after turning on the air conditioning.

A

(A) Very few bubbles observed, then transparent at first, then whitish: "Normal".

(B) The bubbles are numerous: check the unions and consult your CASE Dealer.

B

(C) No bubbles are visible: check the unions and consult your CASE Dealer.

C CT07K015

37

8-19

SECTION 8 - MAINTENANCE/ADJUSTMENTS 3.

Check if the air-conditioning line and hose connectors are dirty or dusty and clean them if necessary.

CT02D235

38

PLASTIC AND RESIN PARTS When cleaning the plastic windows, the console, the instrument panel, the indicators, etc. do not use gasoline, kerosene, paint solvents, etc. Only use water, soap and a soft cloth.

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

8-20

SECTION 8 - MAINTENANCE/ADJUSTMENTS ENGINE TROUBLESHOOTING NOTE: This section shows how to easily diagnose problems relating to the engine and describes the solutions to be adopted. If you are unable to determine the cause of the failure, or if the latter is difficult to rectify, consult your CASE Dealer.

PROBLEM

Engine does not start.

POSSIBLE CAUSE

SOLUTION

Defective starter switch (starter does not run)

Check switch

Defective rotation of starter (starter rotates slowly)

Discharged batteries, starter problems, contaminated or loose wiring connectors

Incorrect viscosity of engine oil

Inspect and replace as necessary

Incomplete air bleeding of fuel system

Completely bleed air

Engine too cold (cold weather)

Preheat the intake air or warm up the coolant

No fuel in fuel tank

Refill

Poor fuel quality

Inspect and replace as necessary

Fuel filter clogged

Clean or replace

Possible seizure in engine Low compression

Consult your CASE Dealer

Defective fuel injection pump Engine stops during operation.

No fuel in fuel tank

Refill

Fuel filter clogged

Clean or replace

Air in the fuel system

Retighten fuel in line connections

Low oil

Refill

Oil filter clogged

Replace oil filter

Low oil viscosity

Replace with oil of viscosity to match temperature

Oil leakage from connections

Tighten connections

Incorrect oil pressure.

Defective oil pressure switch Consult your CASE Dealer Incorrect functioning of oil pump

Exhaust from engine is white or blue.

Excessive oil

Disassemble and repair, replace parts

Excessively low oil viscosity

Replace with correct oil viscosity

Excessive cooling by radiator

Adjust

Incorrect fuel injection timing Consult your CASE Dealer Low compression

8-21

SECTION 8 - MAINTENANCE/ADJUSTMENTS

PROBLEM

Exhaust from engine is black or dark grey.

POSSIBLE CAUSE

SOLUTION

Incorrect fuel

Replace with correct fuel

Incorrect valve clearance

Adjust

Insufficient air intake (air cleaner clogged)

Service the air filter

Defective fuel injection pump Consult your CASE Dealer Low compression Incorrect fuel

Replace with correct fuel

Insufficient air intake

Clean or replace element

Defective fuel injection pump Excessive fuel consumption.

Incorrect spray from fuel injection nozzle Consult your CASE Dealer Incorrect fuel injection timing Low compression Excessive oil

Drain oil to proper level

Low oil viscosity

Replace with oil of viscosity to match temperature

Oil leakage

Retighten and replace parts if necessary

Worn cylinder piston ring

Consult your CASE Dealer

Poor fuel quality

Replace

Damage inside muffler

Replace

Low coolant

Refill

Water leakage

Repair

Worn or damaged belt

Replace

Incorrect mixture of anti-freeze solution

Replace

Excessive engine oil consumption.

Unusual noise (fuel or mechanical).

Engine overheating (water temperature is too high).

Defective radiator Broken fan Defective thermostat

Consult your CASE Dealer

Defective water pump Defective water temperature gauge

Defective battery charge.

Incorrect belt tension

Adjust

Electrical wiring problems

Repair

Defective battery

Replace

Defective regulator Consult your CASE Dealer Defective alternator

8-22

SECTION 8 - MAINTENANCE/ADJUSTMENTS HARDWARE TORQUE INSPECTION MAINTENANCE SPECIFICATION Check .................................................................................................................................................... Every 250 hours (after the first 50 hours during the run-in period) At the end of each working day, check all mounting nuts and screws for tightness and tighten if necessary.

Make sure no hardware items are missing. Replace them, if necessary.

Screw (Ø)

Wrench (mm)

Torque setting (Nm)

Travel reduction gear (*)

M16

24

267-312

Drive sprocket (*)

M16

24

267-312

Idler wheel (*)

M16

24

267-312

Upper roller (*)

M20

30

521-608

Lower roller (*)

M18

27

371-432

Chain guide (*)

M18

27

400-462

Track pad

M20

30

300+120°±5°

Counterweight

M36

55

2260-2450

Turntable (undercarriage)

M20

30

468-545

Turntable (upperstructure)

M20

30

468-545

Swing reduction gear (*)

M20

30

540-630

Engine (*)

M16

24

64-74

M10

17

64-74

M16

24

64-74

M16

24

147-176

M10

17

64-73

M20

30

367-496

Hydraulic reservoir (*)

M20

30

421-471

Fuel tank (*)

M20

30

421-471

Control valve (*)

M16

24

267-312

Hydraulic swivel (*) (on undercarriage)

M12

19

109-127

Lug on hydraulic swivel

M12

19

89-107

Cab

M16

24

71-86

Batteries

M10

17

20-29

Component

Engine mounts (*) Radiator Hydraulic pump (*)

NOTE: Use Loctite 262, or the equivalent, on screws marked (*).

8-23

SECTION 8 - MAINTENANCE/ADJUSTMENTS

NOTES

8-24

SECTION 9

10

ELECTRICAL SYSTEM FUSES IMPORTANT: Before changing fuses or relays, turn the starter switch key to the "Shut down" position.

IMPORTANT: Never replace a fuse with a fuse of a different amperage.

The fuse box is located in the operator’s compartment at the back on the LH side.

CT02F021

1 To access the fuses, remove the cover of the box.

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

NOTE: To remove and install a fuse, use the plastic pliers located inside the box.

NOTE: Two spare fuses (10 amp and 20 amp) are to be found on the inside of the cover.

CT02F022

2

9-1

SECTION 9 - ELECTRICAL SYSTEM FUNCTION OF THE FUSES (1) Memory, cab 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) Working lights ................................................. 15 A (11) Fuel filler pump (if equipped) ......................... 20 A (12) Cigarette lighter, operator’s seat .................... 15 A (13) Overload indicator .......................................... 10 A (14) DC rectifier...................................................... 10 A (15) Rotating beacon (not supplied)...................... 10 A (16) Instrument panel............................................. 10 A (17) Fuel supply pump........................................... 10 A (18) Not used ......................................................... 15 A (19) Hydraulic control cancellation ........................ 10 A (20) Maintenance socket ....................................... 10 A

1

10A

20A

11

2

30A

15A

12

10A

10A

5A

10A

15A

10A

5A

10A

10A

10A

15A

15A

10A

10A

15A

10A

3 4 5 6 7 8 9 10

13 14 15 16 17 18 19 20

CT07M025

3

9-2

SECTION 9 - ELECTRICAL SYSTEM BATTERIES MAINTENANCE SPECIFICATION Checking the charge state.................................................................................................................... Every 250 hours Electrolyte level check .......................................................................................................................... Every 250 hours NOTE: When starting the machine with booster batteries, see "Connecting booster batteries".

!

WARNING

!

Before any operation on the components of the electrical circuit, put the starter switch key in the "Off" (shut down) position. When disconnecting batteries, always disconnect the negative (-) cable first. When reconnecting batteries, always connect the negative (-) cable last.

!

WARNING

!

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

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

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

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

!

WARNING

!

A spark or a naked light can cause the hydrogen in a battery to explode. To prevent explosion, proceed as follows: - When disconnecting battery cables, always disconnect the negative cable (-) first.

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

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

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

!

WARNING

!

Batteries give off explosive gases. Keep all naked flames, sparks and cigarettes away. Ensure adequate ventilation when charging batteries or when using in a confined place. Always protect your eyes when working near batteries.

9-3

SECTION 9 - ELECTRICAL SYSTEM ACCESS TO THE BATTERIES To access the batteries, open the rear LH side door.

Remove the wing screw (1), the washer (2) and the protective matting (3) from the batteries.

3

1 2 CT02F023

4 CHECKING THE CHARGE STATE OF A MAINTENANCE-FREE BATTERY The charge indicator on the battery shows the state of charge of the battery.

If the colour is: Green; the charge is correct.

Black; insufficient charge. Recharge the battery until the indicator turns green.

Transparent (colourless); replace the battery as soon as possible.

CT02F024

5 CHECKING THE ELECTROLYTE LEVEL OF A MAINTENANCE-TYPE BATTERY Remove the cell caps and check the level in each batteries cell. The level should be between 10 and 15 mm above the plates. Add distilled water if necessary, then install the cell caps.

IMPORTANT: When adding distilled water at temperatures below 0°C, the batteries must be charged or the engine run for two hours approximately in order to ensure that the distilled water and the electrolyte are properly mixed.

NOTE: Make sure the battery terminals are clean and coated with grease and that the cables are properly tightened.

CT06M036

6

9-4

SECTION 9 - ELECTRICAL SYSTEM REPLACING THE BATTERIES Removal 1.

Remove the terminal sleeves, disconnect the cables (1) (negative terminal) then the cables (2) (positive terminal).

2 1 2 1

CT02F025

7 2.

Remove the screws (1), the washers (2) and the holding frame (3).

3

1

2 CT02F026

8 3.

Remove the screws (1), the washers (2) and the elbow (3).

4.

Remove the used batteries.

5.

Clean the battery compartment, remove all foreign bodies, clean any spilt electrolyte.

3 1

CT02F027

2 9

9-5

SECTION 9 - ELECTRICAL SYSTEM Installation 1.

Install new batteries. Clean the cables and battery terminals and coat them with grease.

2.

Install the holding frame, the washers and tighten the screws.

3.

Connect the cables (positive terminal), the cables (negative terminal) then install the terminal sleeves.

!

WARNING

!

Do not invert battery terminals. Connect positive cable ends to positive terminals (+) and negative cable ends to negative terminals (-).

CT02F026

!

WARNING

!

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

!

WARNING

!

Never touch the battery terminals with hands, electrolysis can occur inside the human body and damage your vital organs.

9-6

10

SECTION 9 - ELECTRICAL SYSTEM CONNECTING BOOSTER BATTERIES

!

WARNING

!

Connecting auxiliary cables wrongly or short-circuiting batteries terminals can cause an accident. Connect auxiliary starting cables as per the following instructions.

Check that the voltage of the booster batteries is compatible with the machine's electrical system.

1.

Remove the protective mat, if necessary.

2.

Remove the terminal sleeves.

3.

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

4.

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

5.

Start the engine.

6.

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

7.

Install the terminal sleeves.

8.

Install the protective mat, if necessary.

ALTERNATOR MAINTENANCE SPECIFICATION Check .................................................................................................................................................. Every 1000 hours

!

WARNING

!

Whenever carrying out a welding operation on the machine (authorised by the manufacturer and in accordance with his instructions) or any repairs on the electrical system, disconnect the B+ and D+ wires from the alternator. When reconnecting, check the markings on the wires.

IMPORTANT: Do not use steam cleaning equipment or a cleaning solvent to clean the alternator.

Ask your CASE Dealer to check the alternator.

NOTE: Make sure that the terminal protectors are correctly installed.

9-7

SECTION 9 - ELECTRICAL SYSTEM STARTER MOTOR MAINTENANCE SPECIFICATION Check .................................................................................................................................................. Every 1000 hours Ask your CASE Dealer to check the starter motor.

NOTE: Make sure that the terminal protectors are correctly installed.

REPLACING A BULB OPERATOR’S COMPARTMENT LIGHTING 1.

Remove the cover.

CT02C058

11 2.

Remove the bulb and install a bulb of the same wattage (6 W).

3.

Install the lens.

CT02D267

12

9-8

SECTION 9 - ELECTRICAL SYSTEM WORKING LIGHTS ON THE CAB AND ON THE ATTACHMENT 1.

Remove the 4 retaining screws.

CT02D261

13 2.

Tilt the working light and disconnect the plug.

CT02D262

14 3.

Pull the clip outwards, remove the bulb and install a bulb of the same wattage: 55 W for lights on the cab and 70 W for light on the attachment.

IMPORTANT: Never put your fingers on a tungsten iodide bulb.

4.

Install the clip and reconnect the plug.

5.

Put the working light back into position and install the mounting screws.

CT02D263

15

9-9

SECTION 9 - ELECTRICAL SYSTEM ADJUSTING THE WORKING LIGHTS Working lights are adjusted manually.

CAB

CT02D265

16 ATTACHMENT

CT02D264

17

9-10

SECTION 10

2

STORAGE STORING THE MACHINE PREPARATION FOR STORAGE

PERIODIC CHECKS

The following procedure applies when the machine is to be stored for a month or more. Store the machine on flat, level ground, inside a building or, if not possible, outside and covered with a tarpaulin. Before storing the machine, carry out the following operations:

Every month, check:

1.

2.

3.

4.

1.

The battery charge and recharge the batteries if required.

2.

The levels and top up if necessary.

Clean the machine.

3.

Make sure that the machine has no damaged or missing parts. Replace them if necessary.

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

4.

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

5.

Unplug the air filter inlet and the exhaust pipe.

6.

Run the engine at low speed following the starting up procedure and operate the attachment, swing and travel controls.

Retract the cylinder rods as for as possible and lower the boom until the attachment is resting on the ground. Lower the dozer blade (if equipped) to the ground.

Grease the machine thoroughly. The exposed surfaces of the cylinder rods should be greased or covered with a protective film. Consult your CASE Dealer.

NOTE: When the machine resumes service, the film will disappear automatically.

5.

While the engine is still warm, drain the oil sump, replace the oil filter and fill with specified oil.

Check the oil level and add more if necessary.

6.

Clean or replace the air filter element.

7.

Check the level of coolant solution. If the machine is within 100 hours of the next scheduled coolant change, change the coolant now.

8.

Remove the batteries, clean the battery housings and make sure not to leave any traces of acid.

Store the batteries safely in a cool and dry location, where the temperature is higher than 0 °C or disconnect the cable from the negative (-) terminal.

9.

Paint any areas where the paintwork is not good.

!

WARNING

!

Avoid running the engine in a confined place. Make sure there is adequate ventilation at all times..

7.

The grease on the cylinder rods.

8.

Plug the air filter inlet and the exhaust pipe.

10. Plug the air filter inlet and the exhaust pipe.

11. Remove the starter switch key and place a "Do not operate" label on the right-hand control arm and then place the function cancellation lever in the central position (safety bar in inward position).

12. Lock the hoods, side doors and the cab door.

10-1

SECTION 10 - STORAGE STARTING UP AFTER STORAGE 1.

Drain the fuel tank, the pre-filter and the fuel filter, replace the filter elements if necessary.

2.

Fill the fuel tank with suitable fuel, see "Fluids and Lubricants" in section 7.

3.

Install the batteries or reconnect the cable to the negative (-) terminal.

4.

Grease the machine thoroughly.

5.

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

6.

Check the condition of the air conditioning drive belt and replace it if necessary.

7.

Check the level of the cooling system and add more coolant if necessary.

8.

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

9.

Check the travel reduction gears and swing reduction gear oil level and add more oil if necessary.

10. Clean the cylinder rods.

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

!

WARNING

!

Before starting the engine, make sure that all controls are in neutral position. This prevents the machine from moving unexpectedly.

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

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

!

WARNING

!

Check the machine for leaks or for any parts that are broken, defective or missing.

!

WARNING

!

Avoid running the engine in a confined place. Make sure there is adequate ventilation at all times.

10-2

SECTION 11

8

SPECIFICATIONS ENGINE Latest "common rail" engine, in conformity with the European requirements applicable to low fumes emission, in accordance with the directive 97/68/EC. Make and type .....................................................................................................................................ISUZU AI-4HK1X Common rail, turbo, intermediate cooler, fuel cooler.................................................................................................yes Injection...................................................................................................................................... electronically controlled Number of cylinders....................................................................................................................................................... 4 Bore/stroke.........................................................................................................................................115 mm x 125 mm Displacement ....................................................................................................................................................5193 cm3 Cooling................................................................................................................................................................by water Battery starting .............................................................................................................. 2 12 V batteries, 92 A/h WORKING CONDITIONS Speed................................................................................................................................................................1800 rpm EEC 80/1269 power ............................................................................................................................ 114.4 kW/155 hp Engine oil capacity ................................................................................................................................................ 23.1 l Fuel tank capacity .................................................................................................................................................. 265 l Fuel filler pump ............................................................................................................................................. if equipped Engine/pump assembly mounted on flexible mountings.

Filtration in dusty conditions.

Electronically controlled governor.

HYDRAULIC SYSTEM Variable flow piston-type double pump.

Main pump max flow (at 2000 rpm) .................................................................................................2 x 190 l/min Fixed flow pump (pilot circuit).

Max. flow ................................................................................................................................................. 20 l/min Fixed flow pump (dozer blade) (if equipped).

Max. flow ................................................................................................................................................. 69 l/min Working pressure.

Attachment/power boost ...................................................................................................................343/373 bar Oil cooler with air cooling from engine.

High pressure multispiral hoses minimum safety factor.................................... 2 to 4 times the working pressure Self-lubricating hydraulic swivel.

Hydraulic reservoir capacity......................................................................................................................... 120 l Total hydraulic system capacity ................................................................................................................... 205 l CONTROL VALVE Four control valve sections for left-hand travel, boom/bucket and dipper acceleration.

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

One control valve section for the dozer blade (if equipped).

Boom/dipper load holding valves.

11-1

SECTION 11 - SPECIFICATIONS SWING Fixed flow, piston-type pump.

Mechanical disk brake.

Upperstructure swing speed..............................................................................................................................10.6 rpm TRAVEL Two speed hydraulic motors with axial pistons.

Planetary reduction gears.

Low speed...................................................................................................................................................0 to 3.1 km/h High speed..................................................................................................................................................0 to 5.0 km/h Gradeability ...............................................................................................................................................................70% ATTACHMENT Crowd force................................................................................................................................................... 14 100 daN Break-out force (with 2.40 m dipper)............................................................................................................ 12 600 daN

UNDERCARRIAGE One-piece frame with welded components.

Lubricated track rollers and idler wheels.

Grease cylinder track tension system.

Steel tracks ..........................................................................................................600 mm, 700 mm and 800 mm Ground pressure with 600 mm track pads and: (Monobloc boom) ..............................................................................................................................................0.49 bar (Monobloc boom + dozer blade) .......................................................................................................................0.55 bar

SAFETY DEVICES Control for lowering attachments in case of engine failure.

Controls are disabled by lifting the function cancellation lever or the left-hand control arm.

Engine emergency shut-down.

Safety glass, horn.

Safety valves with overload indicator ................................................................................................................. optional Inertia reel type safety belt.

Fire extinguisher.................................................................................................................................................. optional

11-2

SECTION 11 - SPECIFICATIONS OPERATOR'S COMPARTMENT Deluxe operator's seat with armrests, inertia type safety belt, multi-position adjustment and headrest (vibration level III/ISO 7096, 2000 Class EM 6).

Hydraulically assisted controls.

Attachment and swing .............................................................................................................................2 control levers Travel.....................................................................................................................................................2 levers/2 pedals Dozer blade (if equipped) ......................................................................................................................................1 lever Single-speed wiper plus intermittent mode, washers, heating, defrost, ventilation, cab lights, sun shield.

Working lights: One on attachment ................................................................................................................... 24 V, 70 W One on cab ............................................................................................................................... 24 V, 70 W

NOISE LEVELS Guaranteed by the manufacturer.

Outside the operator's compartment (Lwa).

Sound power level 102 dB (A) in accordance with the 2000/14/EC directive.

Inside the operator's compartment (Lpa).

Sound pressure level of 75 dB (A) in accordance with the ISO 6396 (2006/42/EC) standard.

VIBRATION LEVEL INSIDE THE CAB Upper members....................................................................................................................... level lower than 2.5 m/s2 Body ......................................................................................................................................... level lower than 0.5 m/s2

CAB Removable, sound proof, mounted on flexible mountings. Prefitted for radio installation.

Foldaway windscreen. Air conditioning (optional).

Rear window emergency exit. Windshield protection grid (optional).

Sun shield.Cab protection (optional).

WEIGHTS With monobloc boom, 2.40 m dipper, 1050 l backhoe bucket, 600 mm pads, operator and full fuel tank ......................................................................................................................... 23 400 kg With dozer blade add............................................................................................................................................ 900 kg

11-3

SECTION 11 - SPECIFICATIONS BOOM Monobloc boom length........................................................................................................................................5.70 m

DIPPERS Length ..................................................................................................................................1.90 m, 2.40 m and 3.00 m

BACKHOE BUCKETS "SCOOP" BUCKETS (installation with quick coupler) GENERAL PURPOSE* / HEAVY DUTY** / ROCK*** SAE capacity (l)

440

590

750

850

960

1070

1230

1390

Width (mm)

600

750

900

1000

1100

1200

1350

1500

Weight* (kg)

518

574

642

680

730

767

846

904

Weight** (kg)

574

630

707

745

782

841

908

987

Weight*** (kg)

595

651

727

764

801

867

925

"DIRECT" FIT BUCKETS (installation with or without quick coupler) GENERAL PURPOSE* / HEAVY DUTY** / ROCK*** SAE capacity (l)

440

590

750

850

960

1070

1230

1390

Width (mm)

600

750

900

1000

1100

1200

1350

1500

Weight* (kg)

524

578

645

682

731

767

849

905

Weight** (kg)

580

634

710

747

783

841

911

988

Weight*** (kg)

601

655

730

766

802

858

928

DITCH CLEANING

(without cutting edge)

(with cutting edge)

SAE capacity (l)

860

940

860

940

Width (mm)

1830

2130

1830

2130

Weight (kg)

516

570

645

710

DOZER BLADE (if equipped) Width.....................................................................................................................................................................2.80 m Height....................................................................................................................................................................0.61 m Maximum lift height .............................................................................................................................................0.46 m Maximum depth ...................................................................................................................................................0.41 m

11-4

SECTION 11 - SPECIFICATIONS MACHINE OVERALL DIMENSIONS With 5.70 m monobloc boom

CT02F028

1 Dippers 1.90 m 2.40 m 3.00 m (A)............................................................................... 3.08 m........................... 3.14 m ........................... 2.97 m (B)............................................................................... 2.97 m........................... 2.97 m ........................... 2.97 m (C)............................................................................... 8.97 m........................... 8.93 m ........................... 8.85 m (D)............................................................................... 6.74 m........................... 6.70 m ........................... 6.62 m (E)............................................................................... 2.80 m........................... 2.80 m ........................... 2.80 m (F) ............................................................................... 1.40 m........................... 1.40 m ........................... 1.40 m (G) .............................................................................. 1.68 m........................... 1.68 m ........................... 1.68 m (H)............................................................................... 4.46 m........................... 4.46 m ........................... 4.46 m (I) ............................................................................... 3.66 m........................... 3.66 m ........................... 3.66 m (J) ............................................................................... 2.39 m........................... 2.39 m ........................... 2.39 m (K) (standard track pads) ............................................ 0.60 m........................... 0.60 m ........................... 0.60 m (L) (with 600 mm track pads)...................................... 2.99 m........................... 2.99 m ........................... 2.99 m (L) (with 700 mm track pads)...................................... 3.09 m........................... 3.09 m ........................... 3.09 m (L) (with 800 mm track pads)...................................... 3.19 m........................... 3.19 m ........................... 3.19 m (M) .............................................................................. 0.46 m........................... 0.46 m ........................... 0.46 m (N)............................................................................... 1.40 m........................... 1.40 m ........................... 1.40 m

11-5

SECTION 11 - SPECIFICATIONS With 5.70 m monobloc boom and dozer blade

CT02F028A

2 Dippers 1.90 m 2.40 m 3.00 m (A) ............................................................................... 3.08 m ...........................3.14 m ...........................2.97 m (B) ............................................................................... 2.97 m ...........................2.97 m ...........................2.97 m (C) ............................................................................... 9.37 m ...........................9.33 m ...........................9.25 m (D) ............................................................................... 6.74 m ...........................6.70 m ...........................6.62 m (E) ............................................................................... 2.80 m ...........................2.80 m ...........................2.80 m (F) ............................................................................... 1.40 m ...........................1.40 m ...........................1.40 m (G)............................................................................... 1.68 m ...........................1.68 m ...........................1.68 m (H) ............................................................................... 4.17 m ...........................4.17 m ...........................4.17 m (I) ................................................................................ 3.37 m ...........................3.37 m ...........................3.37 m (J)................................................................................ 2.20 m ...........................2.20 m ...........................2.20 m (K) (standard track pads) ............................................ 0.60 m ...........................0.60 m ...........................0.60 m (L) (with 600 mm track pads) ...................................... 2.80 m ...........................2.80 m ...........................2.80 m (L) (with 700 mm track pads) ...................................... 2.90 m ...........................2.90 m ...........................2.90 m (L) (with 800 mm track pads) ...................................... 3.00 m ...........................3.00 m ...........................3.00 m (N) ............................................................................... 1.40 m ...........................1.40 m ...........................1.40 m (O)............................................................................... 2.63 m ...........................2.63 m ...........................2.63 m

11-6

SECTION 11 - SPECIFICATIONS WORKING RANGE BACKHOE ATTACHMENT With 5.70 m monobloc boom

CT02F029

3 Dippers 1.90 m 2.40 m 3.00 m A (Maximum reach) ................................................... 8.92 m........................... 9.37 m ........................... 9.91 m B (Maximum reach at ground level) ........................... 8.73 m........................... 9.18 m ........................... 9.73 m C (Maximum digging depth)....................................... 5.62 m........................... 6.10 m ........................... 6.70 m D (Maximum digging depth over a length of 2.44 m) ......................................... 5.38 m........................... 5.89 m ........................... 6.53 m E (Maximum dump height)......................................... 7.29 m........................... 7.63 m ........................... 8.02 m F (Maximum working height) ................................... 10.17 m......................... 10.52 m ......................... 10.91 m G (Minimum attachment swing radius)....................... 2.82 m........................... 2.54 m ........................... 2.30 m H (Maximum digging depth on a vertical face)........... 5.05 m........................... 5.48 m ........................... 6.07 m

11-7

SECTION 11 - SPECIFICATIONS QUICK COUPLER (optional) DIMENSIONS NEEDED TO FIT THE QUICK COUPLER

!

!

WARNING

The quick coupler described in this manual is designed to be used with CASE buckets. This being said, other buckets may be used, provided the diameter of the pins and the width between the bucket lugs are modified to meet the dimensions needed to fit the quick coupler (pins, washers, bushings, etc.). Consult your CASE Dealer.

Bucket pin diameter

80 mm

Width between lugs

307 mm

Minimum distance between bucket centres

435 mm

Maximum distance between bucket centres

512 mm

WEIGHT 440 kg OVERALL DIMENSIONS

C

B

A CS00J503

4

11-8

A

990 mm

B

580 mm

C

470 mm

SECTION 12 ALPHABETICAL INDEX A

E

Adjusting rocker arm clearance ............................ 8-8 Adjusting the working lights ................................ 9-10 Air conditioning .................................................. 8-17 Air filter .............................................................. 7-40 Air flow direction ....................................... 4-11, 4-12 Air recycling .............................................. 4-11, 4-12 Air vents ............................................................ 4-27 Air-conditioning switch ....................................... 4-12 Alternator............................................................. 9-7 Ashtray.............................................................. 4-18 Auxiliary hydraulic circuits .................................. 5-34

Economy mode switch ......................................... 4-8 Electrical system .................................................. 9-1 Emergency shut down switch ............................... 4-7 Engine ......................................................7-14, 11-1 Engine coolant temperature indicator.................... 4-5 Engine electric circuit indicator lamp ..................... 4-6 Engine hood ...................................................... 4-33 Engine idle speed selector.................................... 4-4 Engine oil pressure indicator lamp ........................ 4-5 Engine operation.................................................. 5-7 Engine throttle button ........................................... 4-4 Engine troubleshooting....................................... 8-21 Environment ........................................................ 7-4

B Backhoe buckets ............................................... 11-4 Batteries .............................................................. 9-3 Battery charge indicator lamp............................... 4-6 Before using the machine..................................... 5-1 Boom ................................................................ 11-4 Boom and bucket right-hand control lever........... 4-14 Bringing the machine up to operating temperature............................. 5-6 C Cab ................................................................... 11-3 Cab door ............................................................. 4-1 Cab light ............................................................ 4-17 Cab protection (F.O.P.S.).............................. 3-5, 8-9 Cab radio compartment...................................... 4-19 Checking for cylinder leakage .............................. 8-9 Checking the machine settings............................. 8-8 Checking the quick coupler latching hook opening.................................... 8-15 Coat hanger hook .............................................. 4-17 Control locking lever.................................... 4-7, 4-13 Controls/Instruments/Accessories ........................ 4-1 Cooling system .................................................. 7-17 D Daily inspections.................................................. 6-2 Decals ................................................................. 3-9 Dipper and upperstructure swing left-hand control lever........................... 4-14 Dippers.............................................................. 11-4 Dozer blade ....................................................... 11-4 Dozer blade control lever ............................ 4-4, 4-16

F Fan and alternator drive belt ................................. 8-6 Fire extinguisher................................................. 8-14 Fluid and lubricant capacities and specifications ............................ 7-4 Fluids and lubricants ............................................ 7-1 Fuel level indicator ............................................... 4-5 Fuel level indicator lamp....................................... 4-6 Fuel system ....................................................... 7-21 Fuel tank............................................................ 4-30 Fuel tank filler pump ........................................... 4-41 Fuel tank filter ...................................................... 8-8 Fuse box............................................................ 4-19 Fuses .................................................................. 9-1 G Glove compartment............................................ 4-18 Grease points ...................................................... 7-5 H Hand signals ...................................................... 3-22 Handling the machine......................................... 5-20 Hardware torque inspection................................ 8-23 Heating and ventilation control.....................4-8, 4-11 Heating, ventilation or air-conditioning control ........................4-8, 4-12 High speed travel switch..............................4-6, 4-10 Horn .................................................................... 4-7 Hourmeter.....................................................4-5, 6-2 Hydraulic system.......................................7-29, 11-1

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SECTION 12 - ALPHABETICAL INDEX I

P

Identification numbers/Machine components......... 2-1 Implement operation and maintenance ................. 3-5 Inspecting and cleaning the machine .................... 8-8 Instrument panel ...........................................4-4, 4-5 Intervals ............................................................... 6-5

Parking the machine .......................................... 5-22 Plastic and resin parts ........................................ 8-20 Position of the operator’s compartment controls and accessories.................................. 4-3 Preheating indicator lamp..................................... 4-6 Preventing risks caused by vibrations ................... 3-4

L Left-hand control arm ........................................... 4-7 Levels ................................................................ 7-12 Load handling .................................................... 5-26 Load handling eyes ............................................ 4-37 Location of option control...................................... 4-8 Locking and unlocking the option pedal .............. 4-16 Lower front window ............................................ 4-26 Lower panels ..................................................... 4-38 Lowering the attachment in the event of a machine failure......................... 5-28 Lubrication/Filters/Fluids....................................... 7-1 M Machine operation.............................................. 5-10 Machine overall dimensions ............................... 11-4 Machine travel.................................................... 5-12 Maintenance/Adjustments .................................... 8-1 Maximum attachment power control ..................... 4-4 N Noise levels ....................................................... 11-3 O Official documents................................................ 1-3 On/Off.......................................................4-11, 4-12 Operating instructions........................................... 5-1 Operating the backhoe bucket ............................ 5-25 Operating the machine ......................................... 5-2 Operating the machine in cold weather ................. 5-9 Operating the machine in hot weather................... 5-9 Operating the machine in water .......................... 5-21 Operating the machine on sloping ground........... 5-21 Operator's compartment..................................... 11-3 Operator's seat................................................... 4-20 Option control....................................................... 4-8 Option pedal ...................................................... 4-15 Optional tool flow selector valve.......................... 4-40 Optional tool supply valves ................................. 4-39 Overheating indicator lamp................................... 4-5 Overload indicator switch...................................... 4-7

12-2

Q Quick coupler..............................................3-5, 11-8 Quick coupler incorrect functioning ....................... 6-4 Quick coupler installation.................................... 5-29 Quick coupler locking and unlocking control switch........................... 4-13 Quick coupler locking and unlocking switch .......... 4-8 Quick coupler servicing instructions ...................... 6-4 Quick tool installation and removal...................... 5-29 R Radiator and oil cooler ......................................... 8-5 Rear right-hand side window .............................. 4-17 Rear view mirrors............................................... 4-28 Releasing pressure in the hydraulic system ........ 7-27 Replacing a backhoe bucket............................... 8-12 Replacing a bulb .................................................. 9-8 Replacing a tooth tip on a backhoe bucket.......... 8-11 Replacing the hydraulic filters and fluid when a hydraulic breaker is used ................... 7-39 Right, left, front and rear of the machine ............... 1-3 Right-hand control arm......................................... 4-4 Rotary light .......................................................... 4-7 Rotary light cable ............................................... 4-35 Run-in period ....................................................... 5-3 S Safety devices ................................................... 11-2 Safety instructions................................................ 3-1 Safety valves ..................................................... 4-38 Safety/Decals/Hand signals.................................. 3-1 Servicing instructions ........................................... 6-1 Servicing intervals ................................................ 6-1 Shimming the backhoe bucket............................ 8-13 Side doors ......................................................... 4-34 Speaker compartments ...................................... 4-19 Specifications..................................................... 11-1 Starter motor........................................................ 9-8 Starter switch ....................................................... 4-4 Steps and access handles.................................... 4-2 Stopping the engine ............................................. 5-8

SECTION 12 - ALPHABETICAL INDEX S Storage ............................................................. 10-1 Storage tray....................................................... 4-18 Storing the machine ........................................... 10-1 Sun shield.......................................................... 4-18 Swing reduction gear ......................................... 7-46 T Temperature............................................. 4-11, 4-12 To the owner ....................................................... 1-1 Tooth tip wear limits on the backhoe bucket........ 8-10 Towing .............................................................. 5-24 Towing hole ....................................................... 4-36 Track rollers and idler wheels ............................... 8-4 Tracks ................................................................. 8-1 Transporting the machine................................... 5-15 Travel control levers and pedals......................... 4-15 Travel reduction gears ....................................... 7-49 Type, serial number and year of manufacture of the machine......................... 2-1 U Undercarriage.................................................... 11-2 Upper hoods...................................................... 4-31 Using an implement other than a bucket............... 3-5 V Ventilation................................................. 4-11, 4-12 Vibration level inside the cab .............................. 11-3 W Weight............................................................... 11-3 Welding on the machine..................................... 8-14 Window-breaker hammer................................... 4-27 Windshield......................................................... 4-24 Windshield defroster ................................. 4-11, 4-12 Windshield washer reservoir .............................. 4-38 Windshield washer switch ............................. 4-6, 4-9 Windshield wiper switch ................................ 4-6, 4-9 Working light switch ...................................... 4-6, 4-9 Working range ................................................... 11-7

12-3

SECTION 12 - ALPHABETICAL INDEX

NOTES

12-4

CASE TECHNICAL MANUALS You can obtain manuals on the operation, maintenance and repair of your machine from your CASE Dealer. To ensure quick and efficient service, consult your CASE Dealer for assistance in ordering the correct manuals for your machine.

Your CASE Dealer can deal with orders for operator’s manuals, parts catalogues and service manuals.

Always give the type and serial number of your machine so that your CASE Dealer can supply you with the right manuals for your machine.

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